Automated Composite Manufacturing

自动化复合材料制造

• 批准号: RGPIN-2020-06810
• 负责人: Shadmehri, Farjad
• 金额: $ 1.68万
• 依托单位: Concordia University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2021
• 资助国家: 加拿大
• 起止时间: 2021-01-01 至 2022-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=741446
• 关键词: Automated; Composite; Manufacturing

With increasing use of composites in aircraft and automotive structures, automated composite manufacturing techniques have become essential and are attracting much interest from industry. In particular, the Automated Fiber Placement (AFP) process provides a new approach to the manufacturing of large-scale complex composite structures in comparison to traditional manufacturing techniques. AFP is a process in which composite tapes are laid onto a tool surface in a layer-by-layer manner and can be used in manufacturing both thermoset and thermoplastic composites. The AFP process has many advantages over traditional techniques such as reducing material waste and increasing rate of deposition etc. Thermoplastic composites, in comparison with thermoset composites, are of special interest due to their superior properties, especially with regards to fatigue and impact issues, infinite shelf life, weldability, toughness, chemical resistance etc. A unique advantage of thermoplastic composites is the possibility of in-situ consolidation that can be achieved using the AFP process alone thus avoiding secondary processes such as autoclave treatments which leads to significant manufacturing cost/energy savings. In addition, the possibility of recycling thermoplastic matrix would categorize thermoplastic composites in the field of green technologies. Two main challenges that impede the wide application of thermoplastic composites are the quality of AFP in-situ consolidated laminates and the throughput of the process. This proposal focuses on quality and throughput improvements via introducing innovative interventions and simulation of AFP in-situ consolidation process. The first intervention is incorporating oscillatory motion to the AFP roller's mechanism to improve shear mixing and enhance bonding between in-situ consolidated composite layers. The second proposed intervention to improve bond strength and quality is adding extra amount of polymer to the AFP tape prior to the in-situ manufacturing. The effect of these interventions will be systematically studied in this research program. Furthermore, this proposal aims to take advantage of recent development of Artificial Intelligence (AI) and Machine Learning (ML) techniques. For the first time, we will develop a data-driven model of in-situ AFP process based on experimental data, capable of considering large number of inputs affecting the quality of the process. This data-driven model can be later exploited for process optimization and control to increase throughput and improve quality. The anticipated technical knowledge and the model developed during the course of this research program will have a big impact on the thermoplastic composites manufacturing technology and will improve Canadian composite industries' competitiveness. Student training during this program is of utmost importance and will help to address the shortage of engineers with expertise in advanced composite manufacturing.

随着复合材料在飞机和汽车结构中的应用越来越多，自动化复合材料制造技术已成为必不可少的，并吸引了工业界的极大兴趣。特别是，与传统的制造技术相比，自动纤维铺放（AFP）工艺为制造大型复杂复合材料结构提供了一种新的方法。AFP是一种将复合材料带以逐层方式铺设在工具表面上的工艺，可用于制造热固性和热塑性复合材料。AFP工艺与传统技术相比具有许多优势，例如减少材料浪费和提高沉积速率等。与热固性复合材料相比，热塑性复合材料因其上级性能而特别令人感兴趣，特别是在疲劳和冲击问题、无限保质期、可焊性、韧性、热塑性复合材料的一个独特优势是可以在-可以单独使用AFP工艺实现原位固结，从而避免了二次工艺，例如导致显著的固化的高压釜处理。制造成本/能源节约。此外，回收热塑性基体的可能性将热塑性复合材料归类于绿色技术领域。阻碍热塑性复合材料广泛应用的两个主要挑战是AFP原位固结层压板的质量和该工艺的生产量。该提案的重点是通过引入创新的干预措施和模拟AFP原位固结过程来提高质量和产量。 第一个干预是将振荡运动结合到AFP辊的机构中，以改善剪切混合并增强原位固结复合层之间的结合。提高粘合强度和质量的第二个拟议干预措施是在原位制造之前向AFP胶带添加额外量的聚合物。本研究计划将系统研究这些干预措施的效果。 此外，该提案旨在利用人工智能（AI）和机器学习（ML）技术的最新发展。我们将首次开发基于实验数据的原位AFP过程的数据驱动模型，能够考虑影响过程质量的大量输入。这种数据驱动的模型可以在以后用于过程优化和控制，以增加产量和提高质量。在本研究计划过程中开发的预期技术知识和模型将对热塑性复合材料制造技术产生重大影响，并将提高加拿大复合材料行业的竞争力。在这个项目中，学生培训至关重要，将有助于解决具有先进复合材料制造专业知识的工程师的短缺问题。