Optimization of automated fiber placement (AFP) process for complex helicopter geometries based on structural considerations

本项目旨在改进各向异性复合材料的分析方法，以优化直升机零件的自动纤维铺放（AFP）工艺。优化目标是在满足复杂谱载荷下的强度要求和疲劳寿命目标的同时最小化重量，同时尊重复合材料的制造约束。这个项目是基于以前的经验，在制造AFP零件的过程中遇到了许多困难。当纤维方向与最佳方向不完全对齐时，这导致了保守的方法和过度设计的部件。其目的是改进制造方法，通过允许更多的零件堆叠变化，从而延长疲劳寿命，减少检查时间和成本。在复杂几何形状的纤维方向上的严格公差（不总是通过AFP实现）迫使增加多次检查。更好地了解复合材料的各向异性将导致更充分的公差，这将更容易实现，从而减少检查要求。

The purpose of this project is to improve analysis methods for anisotropic composites in order to optimizemanufacturing of helicopter parts by the Automated Fiber Placement (AFP) process. Optimization objectivesare to minimize weight while meeting strength requirements and fatigue life targets under complex spectrumloading while respecting composite manufacturing constraints. The project is based on previous experiencewhere many difficulties arose during manufacturing of AFP parts. This led to conservative approaches andoverdesigned parts when fiber directions were not perfectly aligned to the optimal directions. The intent is toimprove manufacturing methods that will lead to increased fatigue life, reduced inspection time and costs byallowing more variation in the layups of parts. Tight tolerances on fiber directions in complex geometries (notalways achievable by AFP) force the addition of multiple inspections. A better understanding of compositeanisotropy will lead to more adequate tolerances that would be more easily achievable and thus reduceinspection requirements.