Optimization of DDP test parameters through DoE for AFP process improvement

Abstract

The optimization of the large number of parameters for the laser-assisted Automated Fiber Placement (AFP) process in order to produce high-quality laminates with high consolidation quality, low deformation and high surface quality is challenging. As a prior step towards this optimization, a closer look on how to quantify the consolidation quality in a time- and cost-effective way using the Double Drum Peel (DDP) test is given in this paper. Algorithms and methods are shown for the data processing of the test bench’s output. The Design of Experiments (DoE) method is used to create experimental plans, develop surrogate models for various responses and to find optimized settings for both the peel angle and peel speed of the DDP test. The methods and results presented in this paper offer a valuable insight of how to measure the consolidation quality and how to use this information for the optimization of AFP processes.