Pub Date : 2025-02-26DOI: 10.1016/j.compositesa.2025.108815
Jordi Farjas , Daniel Sanchez-Rodriguez , Sihem Zaidi , Didina-Ramona-Casandra Cârstea , Ahmed Mohamed Saleh Abd Elfatah , Andrei Rotaru , Josep Costa
A recurring problem when curing thick specimen carbon-fibre-reinforced polymers is the formation of thermal gradients. Thermal gradients can lead to heterogeneous properties, overcuring and, in some cases, matrix degradation. To address this problem, we have developed a general-purpose analytical solution that allows one to predict the maximum temperature difference within a specimen when the curing reaction takes place under isothermal conditions. The analytical solution is specifically tailored to deal with standard conditions in the manufacture of composites and can be applied to different resins and prepregs. In addition, it allows one to determine the conditions for when a thermal runaway will occur. The analytical solution was validated by comparing the analytical predictions with numerical and experimental results.
{"title":"Analytical prediction of the thermal overheating in curing thick layers of fibre-reinforced thermosets","authors":"Jordi Farjas , Daniel Sanchez-Rodriguez , Sihem Zaidi , Didina-Ramona-Casandra Cârstea , Ahmed Mohamed Saleh Abd Elfatah , Andrei Rotaru , Josep Costa","doi":"10.1016/j.compositesa.2025.108815","DOIUrl":"10.1016/j.compositesa.2025.108815","url":null,"abstract":"<div><div>A recurring problem when curing thick specimen carbon-fibre-reinforced polymers is the formation of thermal gradients. Thermal gradients can lead to heterogeneous properties, overcuring and, in some cases, matrix degradation. To address this problem, we have developed a general-purpose analytical solution that allows one to predict the maximum temperature difference within a specimen when the curing reaction takes place under isothermal conditions. The analytical solution is specifically tailored to deal with standard conditions in the manufacture of composites and can be applied to different resins and prepregs. In addition, it allows one to determine the conditions for when a thermal runaway will occur. The analytical solution was validated by comparing the analytical predictions with numerical and experimental results.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108815"},"PeriodicalIF":8.1,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143526681","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-26DOI: 10.1016/j.compositesa.2025.108819
Chongzhen Du , Chuanzhen Huang , Hanlian Liu , Xinyao Cui , Shijie Li , Dun Liu , Zhen Wang , Longhua Xu , Shuiquan Huang
The development of ceramic cutting tools usually focused on the optimization of mechanical properties, while ignoring the heat problem during cutting. Aiming at the problem of reducing tool life caused by thermal wear in dry machining, a design method of micro-laminated ceramic tool with thermal barrier function was proposed. Thermal barrier performance evaluation coefficients and , which represent the change of cutting temperature and heat flux per unit thickness, were established for micro-laminated ceramic tools. The effects of material properties and thermal barrier thickness on the thermal barrier performance of cutting tools were characterized. A micro-laminated ceramic tool with good mechanical properties and thermal barrier function was prepared by coupling the surface layer of micro-nano composite thermal barrier with a ductile metal toughening matrix layer. and indicated that the thermal barrier performance deteriorated with time. In the late turning process, the thermal barrier performance mainly came from the hindering effect on heat flux and the influence on temperature distribution. Along the tool-chip contact length, the thermal barrier performance was better at the location away from the main cutting edge. The clean dry turning test showed that compared with SG4, the AWZT with thermal barrier function suppressed thermal wear, improved machining surface quality and prolonged tool life by 56.8%. The development of thermal barrier functional micro-laminated ceramic cutting tools provides a new approach for the design of clean dry processing ceramic composite cutting tool materials, and has important guiding significance for the development of high-performance cutting tools.
{"title":"A design method based on thermal barrier performance evaluation coefficients of micro-laminated ceramic cutting tool materials for clean dry machining","authors":"Chongzhen Du , Chuanzhen Huang , Hanlian Liu , Xinyao Cui , Shijie Li , Dun Liu , Zhen Wang , Longhua Xu , Shuiquan Huang","doi":"10.1016/j.compositesa.2025.108819","DOIUrl":"10.1016/j.compositesa.2025.108819","url":null,"abstract":"<div><div>The development of ceramic cutting tools usually focused on the optimization of mechanical properties, while ignoring the heat problem during cutting. Aiming at the problem of reducing tool life caused by thermal wear in dry machining, a design method of micro-laminated ceramic tool with thermal barrier function was proposed. Thermal barrier performance evaluation coefficients <span><math><mrow><msub><mi>Y</mi><mrow><mi>heat</mi></mrow></msub></mrow></math></span> and <span><math><mrow><msub><mi>Y</mi><mrow><mi>temp</mi></mrow></msub></mrow></math></span>, which represent the change of cutting temperature and heat flux per unit thickness, were established for micro-laminated ceramic tools. The effects of material properties and thermal barrier thickness on the thermal barrier performance of cutting tools were characterized. A micro-laminated ceramic tool with good mechanical properties and thermal barrier function was prepared by coupling the surface layer of micro-nano composite thermal barrier with a ductile metal toughening matrix layer. <span><math><mrow><msub><mi>Y</mi><mrow><mi>heat</mi></mrow></msub></mrow></math></span> and <span><math><mrow><msub><mi>Y</mi><mrow><mi>temp</mi></mrow></msub></mrow></math></span> indicated that the thermal barrier performance deteriorated with time. In the late turning process, the thermal barrier performance mainly came from the hindering effect on heat flux and the influence on temperature distribution. Along the tool-chip contact length, the thermal barrier performance was better at the location away from the main cutting edge. The clean dry turning test showed that compared with SG4, the AWZT with thermal barrier function suppressed thermal wear, improved machining surface quality and prolonged tool life by 56.8%. The development of thermal barrier functional micro-laminated ceramic cutting tools provides a new approach for the design of clean dry processing ceramic composite cutting tool materials, and has important guiding significance for the development of high-performance cutting tools.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108819"},"PeriodicalIF":8.1,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529198","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-26DOI: 10.1016/j.compositesa.2025.108828
Mu Wang , Xiaosong Jiang , Hongliang Sun , Rui Shu , Min Zou , Yu Jiao , Zixuan Wu , Liu Yang
A heterogeneous laminated structure (HLS) design, complemented with an interlayer ordered structure (IOS), combined with heterogeneous powder gradient stacking (HPGS) and flake powder metallurgy (FPM) processes, results in the construction of a heterogeneous laminated micro-nanostructure (HLMS) with HLS and IOS of Cu/Ti3SiC2/C composites. Systematic investigation was conducted to explore the sources and contributions to improve the strength and resistance of the composites. Under applied loads, the HLS and IOS work synergistically. The refined grain orientation within the HLS reinforces the non-uniform deformation at interfaces, facilitating the interaction between strain gradients and geometrically necessary dislocations (GND), thereby enhancing energy absorption or dissipation during fracture. Meanwhile, the highly aligned reinforcement particles (RP) in the IOS help coordinate plastic deformations, reduce local stress concentrations, and optimize electron transport pathways to improve their performance. Results corroborate the assertion that this innovative HLMS structure design strategy is a highly valuable approach for the development of hetero-structured materials.
{"title":"Mechanical and electrical conductivity of Cu-10Ti3SiC2/Cu-3GFs@Cu composites by heterogeneous laminated micro-nanostructure design","authors":"Mu Wang , Xiaosong Jiang , Hongliang Sun , Rui Shu , Min Zou , Yu Jiao , Zixuan Wu , Liu Yang","doi":"10.1016/j.compositesa.2025.108828","DOIUrl":"10.1016/j.compositesa.2025.108828","url":null,"abstract":"<div><div>A heterogeneous laminated structure (HLS) design, complemented with an interlayer ordered structure (IOS), combined with heterogeneous powder gradient stacking (HPGS) and flake powder metallurgy (FPM) processes, results in the construction of a heterogeneous laminated micro-nanostructure (HLMS) with HLS and IOS of Cu/Ti<sub>3</sub>SiC<sub>2</sub>/C composites. Systematic investigation was conducted to explore the sources and contributions to improve the strength and resistance of the composites. Under applied loads, the HLS and IOS work synergistically. The refined grain orientation within the HLS reinforces the non-uniform deformation at interfaces, facilitating the interaction between strain gradients and geometrically necessary dislocations (GND), thereby enhancing energy absorption or dissipation during fracture. Meanwhile, the highly aligned reinforcement particles (RP) in the IOS help coordinate plastic deformations, reduce local stress concentrations, and optimize electron transport pathways to improve their performance. Results corroborate the assertion that this innovative HLMS structure design strategy is a highly valuable approach for the development of hetero-structured materials.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108828"},"PeriodicalIF":8.1,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529196","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Triply periodic minimal surface (TPMS) lattices, known for their high surface area density, significantly influence mechanical properties but have not been fully explored under tensile loads. Evaluating different material and lattice design combinations through computational or experimental methods can be time-intensive. This study introduces a framework for quickly estimating key tensile properties in 3D-printed gyroid and diamond lattices based on structure weight, cell size, and relative density. Specimens were 3D-printed using acrylonitrile butadiene styrene (ABS) and short Kevlar fiber-reinforced ABS through a filament-based extrusion process, showing improved mechanical performance with dual-material combinations. A detailed comparison of homogeneous and composite sandwich specimens along with failure analysis of different geometries revealed notable enhancements in tensile properties. Furthermore, a random forest machine learning model was trained on experimental data, providing a simple yet accurate tool for predicting mechanical properties. This model supports the expansion of machine learning-driven approaches in the design of lattice-structures.
{"title":"Evaluation of tensile properties of 3D-printed lattice composites: Experimental and machine learning-based predictive modelling","authors":"Itkankhya Mahapatra , Niranjan Chikkanna , Kumar Shanmugam , Jayaganthan Rengaswamy , Velmurugan Ramachandran","doi":"10.1016/j.compositesa.2025.108823","DOIUrl":"10.1016/j.compositesa.2025.108823","url":null,"abstract":"<div><div>Triply periodic minimal surface (TPMS)<!--> <!-->lattices, known for their high surface area density, significantly influence mechanical properties but have not been fully explored under tensile loads. Evaluating different material and lattice design combinations through computational or experimental methods can be time-intensive. This study introduces a framework for quickly estimating key tensile properties in 3D-printed gyroid and diamond lattices based on structure weight, cell size, and relative density. Specimens were 3D-printed using acrylonitrile butadiene styrene (ABS) and short Kevlar fiber-reinforced ABS through a filament-based extrusion process, showing improved mechanical performance with dual-material combinations. A detailed comparison of homogeneous and composite sandwich specimens along with failure analysis of different geometries revealed notable enhancements in tensile properties. Furthermore, a random forest machine learning model was trained on experimental data, providing a simple yet accurate tool for predicting mechanical properties. This model supports the expansion of machine learning-driven approaches in the design of lattice-structures.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108823"},"PeriodicalIF":8.1,"publicationDate":"2025-02-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578128","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-25DOI: 10.1016/j.compositesa.2025.108824
Kaixin Xia , Fengrui Liu , Yu Gong , Xinxin Qi , Linjuan Wang , Libin Zhao , Ning Hu
The four-point asymmetric end-notched flexure (4AENF) test under shear loading often involves a mode I component, making it a representative mixed-mode I/II delamination problem. The 4AENF configuration reflects the general delamination behavior in defective laminates, emphasizing the need to characterize interlaminar fracture toughness. Despite its importance, research on 4AENF is limited, and existing models overlook interlaminar friction. This study develops a theoretical model based on Timoshenko beam theory and a two-point friction assumption, enabling analytical calculation of total strain energy release rate (SERR) for any 4AENF configuration, explicitly considering interlaminar friction. Experimental tests and finite element method (FEM) analyses validate the model, using unidirectional (UD) symmetric, UD asymmetric, and multidirectional (MD) asymmetric laminates. Theoretical predictions, experimental results, and FEM analyses are compared, confirming the model’s applicability and highlighting the effects of interlaminar friction.
{"title":"Analytical modeling for four-point asymmetric end-notched flexure delamination test of composite laminates considering interlaminar friction","authors":"Kaixin Xia , Fengrui Liu , Yu Gong , Xinxin Qi , Linjuan Wang , Libin Zhao , Ning Hu","doi":"10.1016/j.compositesa.2025.108824","DOIUrl":"10.1016/j.compositesa.2025.108824","url":null,"abstract":"<div><div>The four-point asymmetric end-notched flexure (4AENF) test under shear loading often involves a mode I component, making it a representative mixed-mode I/II delamination problem. The 4AENF configuration reflects the general delamination behavior in defective laminates, emphasizing the need to characterize interlaminar fracture toughness. Despite its importance, research on 4AENF is limited, and existing models overlook interlaminar friction. This study develops a theoretical model based on Timoshenko beam theory and a two-point friction assumption, enabling analytical calculation of total strain energy release rate (SERR) for any 4AENF configuration, explicitly considering interlaminar friction. Experimental tests and finite element method (FEM) analyses validate the model, using unidirectional (UD) symmetric, UD asymmetric, and multidirectional (MD) asymmetric laminates. Theoretical predictions, experimental results, and FEM analyses are compared, confirming the model’s applicability and highlighting the effects of interlaminar friction.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108824"},"PeriodicalIF":8.1,"publicationDate":"2025-02-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520270","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-25DOI: 10.1016/j.compositesa.2025.108818
Olga Smerdova, Chenghao Chai, Ismail Kolimi, Noël Brunetière
{"title":"Variability in sliding behaviour of carbon fibre tows investigated by Discrete Element Method and experiments","authors":"Olga Smerdova, Chenghao Chai, Ismail Kolimi, Noël Brunetière","doi":"10.1016/j.compositesa.2025.108818","DOIUrl":"10.1016/j.compositesa.2025.108818","url":null,"abstract":"","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108818"},"PeriodicalIF":8.1,"publicationDate":"2025-02-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529199","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-24DOI: 10.1016/j.compositesa.2025.108826
Fengdong Teng, Na Li, Ying Yuan, Junrong Yu, Yan Wang, Zuming Hu
The complex preparation process and high shrinkage of poly(p-phenylene terephthalamide) (PPTA) aerogel limit its wider application. Herein, PPTA and heterocyclic aramid (HPPTA) prepolymer were secondary polymerized to obtain Block-PPTA (BPPTA) with both rigid and flexible segments in the molecular chain. The rigid and flexible segments in molecular chain under non-solvent enable the rapid transformation of BPPTA solutions into well-shaped BPPTA gels. The BPPTA aerogel exhibits the advantages of low shrinkage, high thermal insulation, and high mechanical strength. Then, a small amount of MXene and AgNWs were attached to the surface of BPPTA aerogels by layer-by-layer spraying method, which not only enhanced the flame retardancy capability of the aerogels, but also made organic aerogels possible to be applied in the fields of electromagnetic interference shielding and thermoelectric conversion. This work provides an ideal strategy for the efficient preparation of low shrinkage para aramid aerogels and expands the application areas of aerogels.
{"title":"Efficient preparation and multifunctional application of low shrinkage para aramid aerogels","authors":"Fengdong Teng, Na Li, Ying Yuan, Junrong Yu, Yan Wang, Zuming Hu","doi":"10.1016/j.compositesa.2025.108826","DOIUrl":"10.1016/j.compositesa.2025.108826","url":null,"abstract":"<div><div>The complex preparation process and high shrinkage of poly(p-phenylene terephthalamide) (PPTA) aerogel limit its wider application. Herein, PPTA and heterocyclic aramid (HPPTA) prepolymer were secondary polymerized to obtain Block-PPTA (BPPTA) with both rigid and flexible segments in the molecular chain. The rigid and flexible segments in molecular chain under non-solvent enable the rapid transformation of BPPTA solutions into well-shaped BPPTA gels. The BPPTA aerogel exhibits the advantages of low shrinkage, high thermal insulation, and high mechanical strength. Then, a small amount of MXene and AgNWs were attached to the surface of BPPTA aerogels by layer-by-layer spraying method, which not only enhanced the flame retardancy capability of the aerogels, but also made organic aerogels possible to be applied in the fields of electromagnetic interference shielding and thermoelectric conversion. This work provides an ideal strategy for the efficient preparation of low shrinkage para aramid aerogels and expands the application areas of aerogels.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108826"},"PeriodicalIF":8.1,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143508861","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-24DOI: 10.1016/j.compositesa.2025.108822
Umeir Khan , Vincent K. Maes , Robert Hughes , Jon Wright , Petar Zivkovic , Turlough McMahon , James Kratz
Applying a Deep Learning-based framework has enabled macroscale waviness of Non-Crimp Fabric preforms to be quantified through analysis of in-factory photographs in a fast (∼45 s total processing time per photo) and straightforward way. Historically, image processing techniques, i.e. 2D Fast Fourier Transforms have been used to trace waviness. However, these approaches show shortcomings when applied to visually-complex surfaces, i.e. stitched preforms. In this study, a U-Net model was trained to segment tow and gap regions from in-factory photographs. Applying the model enabled waviness tracings that were then numerically parameterisation. Further stress-testing of the technique was used to interrogate the waviness in (a) visually-similar photographs, and (b) those obtained with compromised imaging conditions. The key finding from this study is that Deep Learning has shown potential in enabling a rapid and cost-effective form of quantitative inspection.
{"title":"In-plane waviness parameterisation from in-factory photographs of non-crimp fabrics","authors":"Umeir Khan , Vincent K. Maes , Robert Hughes , Jon Wright , Petar Zivkovic , Turlough McMahon , James Kratz","doi":"10.1016/j.compositesa.2025.108822","DOIUrl":"10.1016/j.compositesa.2025.108822","url":null,"abstract":"<div><div>Applying a Deep Learning-based framework has enabled macroscale waviness of Non-Crimp Fabric preforms to be quantified through analysis of in-factory photographs in a fast (∼45 s total processing time per photo) and straightforward way. Historically, image processing techniques, i.e. 2D Fast Fourier Transforms have been used to trace waviness. However, these approaches show shortcomings when applied to visually-complex surfaces, i.e. stitched preforms. In this study, a U-Net model was trained to segment tow and gap regions from in-factory photographs. Applying the model enabled waviness tracings that were then numerically parameterisation. Further stress-testing of the technique was used to interrogate the waviness in (a) visually-similar photographs, and (b) those obtained with compromised imaging conditions. The key finding from this study is that Deep Learning has shown potential in enabling a rapid and cost-effective form of quantitative inspection.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108822"},"PeriodicalIF":8.1,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143511929","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-24DOI: 10.1016/j.compositesa.2025.108825
Xiaokang Xu , Liang Cheng , Zhijia Cai , Jiangxiong Li , Yinglin Ke
Automated Fiber Placement (AFP) offers significant advantages in manufacturing large aircraft structures but is prone to defects impacting product quality and mechanical performance. Lay-up Pressure Error (LPE), influenced by various factors, notably lay-up pressure, affects AFP quality. Our study focuses on a heavy-duty robot with pre-positioned lay-up mechanisms for AFP. We analyze the impact of robot and end effector (AFP head) errors on LPE, developing analytical models for compaction rollers and prepreg to establish constitutive relationships. A Generalized Tool-tip Error (GTE) incorporating mold path point offsets is formulated. Additionally, models for joint torsion and bending deformation, considering end forces and robot gravity, are established. Mapping joint errors to AFP robot end-effector errors (ARE) is achieved using extended Jacobian matrices. We comprehensively analyze error effects on LPE and establish an optimization index for robot pose to mitigate LPE. Experimental results validate the effectiveness of our optimization method in enhancing lay-up pressure uniformity, accuracy, and overall quality while reducing defects.
{"title":"Multi-source lay-up error analysis and lay-up pressure optimization for robotic automated fiber placement (AFP)","authors":"Xiaokang Xu , Liang Cheng , Zhijia Cai , Jiangxiong Li , Yinglin Ke","doi":"10.1016/j.compositesa.2025.108825","DOIUrl":"10.1016/j.compositesa.2025.108825","url":null,"abstract":"<div><div>Automated Fiber Placement (AFP) offers significant advantages in manufacturing large aircraft structures but is prone to defects impacting product quality and mechanical performance. Lay-up Pressure Error (LPE), influenced by various factors, notably lay-up pressure, affects AFP quality. Our study focuses on a heavy-duty robot with pre-positioned lay-up mechanisms for AFP. We analyze the impact of robot and end effector (AFP head) errors on LPE, developing analytical models for compaction rollers and prepreg to establish constitutive relationships. A Generalized Tool-tip Error (GTE) incorporating mold path point offsets is formulated. Additionally, models for joint torsion and bending deformation, considering end forces and robot gravity, are established. Mapping joint errors to AFP robot end-effector errors (ARE) is achieved using extended Jacobian matrices. We comprehensively analyze error effects on LPE and establish an optimization index for robot pose to mitigate LPE. Experimental results validate the effectiveness of our optimization method in enhancing lay-up pressure uniformity, accuracy, and overall quality while reducing defects.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108825"},"PeriodicalIF":8.1,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529197","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Carbon fiber reinforced polymer (CFRP) tube is utilized in large aperture deployable space antennas for its superior material properties. Impact damages on CFRP tube can significantly impair the load-bearing capacity of the tubes. Efficient and convenient non-destructive evaluation method of impact damage in CFRP tubes is essential. This study develops a high-frequency eddy current testing (HF ECT) finite element analysis method that accounts for both the dielectric properties and anisotropic conductivity of CFRP, and establishes a fiber bundle model that explains the operating mechanism of displacement current and eddy currents in CFRP, offering guidance for predicting HF ECT signals in CFRP. A high signal-to-noise ratio mutual differential Bobbin probe is developed specifically for detecting impact damage in CFRP tubes. A HF ECT experiment system is constructed and validated using impact damages induced by a force hammer, demonstrating the effectiveness of method and probe, and the invisible impact defect is detected successfully.
{"title":"Impact damage detection on carbon fiber reinforced polymer tube by a mutual differential Bobbin probe","authors":"Wei Guo , Lihua Guo , Hao Xu , Weijun Zhu , Shejuan Xie , Zhenmao Chen , Toshiyuki Takagi , Tetsuya Uchimoto","doi":"10.1016/j.compositesa.2025.108806","DOIUrl":"10.1016/j.compositesa.2025.108806","url":null,"abstract":"<div><div>Carbon fiber reinforced polymer (CFRP) tube is utilized in large aperture deployable space antennas for its superior material properties. Impact damages on CFRP tube can significantly impair the load-bearing capacity of the tubes. Efficient and convenient non-destructive evaluation method of impact damage in CFRP tubes is essential. This study develops a high-frequency eddy current testing (HF ECT) finite element analysis method that accounts for both the dielectric properties and anisotropic conductivity of CFRP, and establishes a fiber bundle model that explains the operating mechanism of displacement current and eddy currents in CFRP, offering guidance for predicting HF ECT signals in CFRP. A high signal-to-noise ratio mutual differential Bobbin probe is developed specifically for detecting impact damage in CFRP tubes. A HF ECT experiment system is constructed and validated using impact damages induced by a force hammer, demonstrating the effectiveness of method and probe, and the invisible impact defect is detected successfully.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108806"},"PeriodicalIF":8.1,"publicationDate":"2025-02-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143511928","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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