Optimizing the lay-up of composite tapes based on improved geodesic strategy for automated tape placement

Abstract

The use of composite materials in aerospace, automotive and ship industry allows manufacturing lighter and more efficient mechanical structures. The major limiting factors are the high-manufacturing costs and low-production rates. Automated tape placement is one alternative process to overcome the limiting factors. Due to the complex contour of the mandrel, the lay-up paths of the contiguous tapes are not parallel along their lengths, which eventually introduce gaps or overlaps between the edges of tapes. Overlaps and excessive gaps are undesirable as they will decrease the strength of the resulting composite member. In this paper, a novel trajectory planning method for automated tape placement, entitled improved geodesic strategy, is proposed. The strategy aims to optimize the relationship between adjacent tapes. At the same time, the distortion of composite tape is also specified in order to prevent wrinkling. The principle and characteristic of the algorithm are presented. The method is investigated on the airfoil of an unmanned aerial vehicle and some of the results are presented in this paper.