Manufacturing and Advanced Simulation of Continuous Tow Shearing (MASCoTS)

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The use of fibre steering to enhance composite structural performance has been seen as having significant potential for reducing material use and reduction in manufacturing costs. It also has been shown to have capabilities for aero-elastic tailoring. This allows an aircraft wing to bend with a reduced twist. Reducing twist allows the wing to be more efficient over a range of wind speeds. This will have an impact on environmental emissions and improve the economic viability in aerospace structures. This could also be extended into other sectors like automotive and wind energy.Current solutions for fibre steering are automatic tape laying (ATL) and tailored fibre placement (TFP) These have both of limitations. ATL cannot steer with a tight radius and steering causes fibre wrinkling and gaps, compromising the structural performance. TFP is a slow process so cannot deposit material fast enough for anything of a significant size. Also the stitching used compromises the structural performance.iCOMAT have created a new tape laying process, continuous tow shearing (CTS) which promises to rival the speed of ATL but without the wrinkling and gaps. It also can lay around tight radii (100mm). However there is an issue that commercial software does not exist to simplify design, analysis and optimisation of structures using CTS.The project is aiming to develop the prototype CTS head design to a level where it can be introduced to industrial applications. In parallel to this development MSC Software will develop design, analysis and optimisation tools to make it accessible to prospective users. They will also write a tool translating the final design back into fibre paths for the CTS head to follow, completing the "digital thread" in this process. DaptaBlade will develop multi-disciplinary software which will enable coupling of a wing structural model with fluid dynamics analyse to perform aeroelastic tailoring.The project will also create demonstrator structures which will be used to verify the analysis and manufacturing software. These will be structurally tested at TWI.