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

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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.