X-ray micro-computed tomography for mechanical behaviour analysis of Automated Fiber Placement (AFP) laminates with integrated gaps and overlaps

IF 6.3 2区材料科学 Q1 MATERIALS SCIENCE, COMPOSITES

Composite Structures Pub Date : 2024-09-23 DOI:10.1016/j.compstruct.2024.118601

Fabian Diemar , John Holmes , Silvano Sommacal , David Aparici-Böhlke , Benno Böckl , Klaus Drechsler , Paul Compston

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引用次数: 0

Abstract

Automated Fiber Placement (AFP) is a manufacturing technique widely used for the serial production of aerospace parts. A deep understanding of the effect of lay-up defects is crucial for part and lay-up design. Currently, numerical models for structural simulation lack a precise representation of the internal structure of AFP laminates, which is crucial for understanding the impact of defects on mechanical properties. This paper presents a novel approach based on high-resolution micro-computed tomography (micro-CT) scans from specimens manufactured with AFP, which automatically creates a mesoscale numerical model incorporating as-fabricated defect morphologies. The hexahedral mesh, generated from the segmented plies of the micro-CT volume, accounts for ply thickness and out-of-plane fiber orientation. This approach is verified with mechanical testing and digital image correlation (DIC) under tensile loading. The simulation results align closely with experimental testing and accurately illustrate the influence of fiber waviness in various defect configurations, such as gaps and overlaps. The study shows that lay-up defects can lead to knockdown factors of up to 12% in tensile properties, with each defect creating a distinct pattern in the local strain. This model can serve as a benchmark for further numerical simulations and surrogate models of defect configurations under varying loading conditions.

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利用 X 射线微型计算机断层扫描技术分析集成间隙和重叠的自动纤维铺放 (AFP) 层压板的机械性能

自动纤维铺放（AFP）是一种广泛应用于航空航天零件批量生产的制造技术。深入了解铺层缺陷的影响对于零件和铺层设计至关重要。目前，用于结构模拟的数值模型缺乏对 AFP 层压板内部结构的精确表示，而这对于了解缺陷对机械性能的影响至关重要。本文介绍了一种基于高分辨率微型计算机断层扫描（micro-CT）的新方法，该方法从使用 AFP 制造的试样中自动创建包含制造缺陷形态的中尺度数值模型。六面体网格由微型计算机断层扫描体积的分段层生成，考虑了层厚度和平面外纤维取向。在拉伸加载条件下，该方法通过机械测试和数字图像相关性（DIC）进行了验证。模拟结果与实验测试结果非常吻合，并准确地说明了纤维波浪在间隙和重叠等各种缺陷配置中的影响。研究表明，铺层缺陷可导致拉伸性能下降高达 12%，每个缺陷都会在局部应变中产生不同的模式。该模型可作为进一步数值模拟和不同加载条件下缺陷配置替代模型的基准。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Composite Structures 工程技术-材料科学：复合

CiteScore

12.00

自引率

12.70%

发文量

1246

审稿时长

78 days

期刊介绍： The past few decades have seen outstanding advances in the use of composite materials in structural applications. There can be little doubt that, within engineering circles, composites have revolutionised traditional design concepts and made possible an unparalleled range of new and exciting possibilities as viable materials for construction. Composite Structures, an International Journal, disseminates knowledge between users, manufacturers, designers and researchers involved in structures or structural components manufactured using composite materials. The journal publishes papers which contribute to knowledge in the use of composite materials in engineering structures. Papers deal with design, research and development studies, experimental investigations, theoretical analysis and fabrication techniques relevant to the application of composites in load-bearing components for assemblies, ranging from individual components such as plates and shells to complete composite structures.