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

本研究的目的是改进各向异性复合材料的分析方法，以优化直升机零部件的自动铺丝工艺。优化目标是在满足复合材料制造约束的同时，在满足强度要求和复杂谱载荷下的疲劳寿命目标的同时，使重量最小化。该项目是基于以往的经验，其中许多困难出现在制造AFP部分。这导致了保守的方法和过度设计的部分时，纤维方向没有完全对齐的最佳方向。其目的是改进制造方法，通过允许零件的铺层有更多的变化，增加疲劳寿命，减少检查时间和成本。复杂几何结构中光纤方向的严格公差（AFP并非总能实现）迫使增加多个检测。更好地理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.