Numeric optimization of in-situ consolidated panels with different tape sequence strategies

Abstract

Automated fibre placement with in-situ consolidation is a fast and flexible manufacturing process for thermoplastic composites, though high thermal gradients and inhomogeneous heating combined with semi-crystalline matrix behaviour create high warping and internal stress. At the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt – DLR) in Stuttgart, simulations were implemented to predict the influence of the manufacturing process on the final warping and stress. The first step to optimize the process was the modification of the sequence, in which the tapes were placed. The results were verified against panels manufactured in the same sequence. The warping was measured using 3D-scans. Finally, an optimal tape laying sequence with minimal warping was determined.