Process Simulation of the In-Situ Automated Fiber Placement Process for Thermoplastic Composites

Abstract

Thermoplastic composites offer new manufacturing processes over composites with thermoset matrix. Since the prepreg material can melt, be formed and solidify in a short amount of time, processes like automated tape placement with in-situ consolidation are viable. However, matrix materials like PEEK and PPS pose challenges due to their high process temperature and their semi-crystalline nature. Combined with the highly dynamic process the behaviour of the part during and after manufacturing is complex to predict and to simulate. At the DLR in Stuttgart a method for simulating plane and curved parts was developed. Using a moving boundary condition for the laser of the AFP-machine, the deformation and interlaminar shear stress can be predicted and the danger for process-induced damage like delamination estimated. This work will help to minimize tolerances and initial costs of parts and contributes to the development of a full digital twin for the entire manufacturing process.