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To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. 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引用次数: 0
摘要
栅格加劲连续纤维增强复合材料板是制造轻质结构的一个极具吸引力的选择,因为它可以针对各种应用进行定制,并具有较高的特定性能。然而,面板加劲件和加劲件交叉点导致模具复杂度高,相应的实施成本也高。这些因素限制了此类结构在复合材料行业中的应用。之前的研究已经证明,通过直接数字化制造,使用 E 玻璃/PET 混合丝束可以生产出高质量、高纵横比的横梁,这些横梁代表了单个网格加强筋。此外,先前的初步研究还证明了使用相同方法制造双向连续纤维网格交叉点的潜力。为了扩展之前通过直接数字化制造生产网格加强筋的成果,并从根本上降低对模具的要求,本成果对两种定位和加固方法(喷嘴和滚筒)进行了比较。这两种工艺都基于混合纱喂料。通过喷嘴进行挤压已被证明可以通过应用固结的局部变化实现网格交叉控制,并可作为基准工艺。但是,这种方法需要连续的铺放路径,以形成完整的网格加劲板,因为没有实现切割和重新启动的机制。另外,新开发的安装在六轴机器人上的集切割和重新进料功能于一体的贴片头也有可能提高路径贴片的效率。这两种技术用于生产类似的网格复合加劲件,以评估生产网格交叉的有效性。通过测量几何形状、纤维体积分数和空隙分数,比较两种末端效应器的沉积率,并确定相关网格加劲件和交叉点的质量。
Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling
Grid stiffened continuous fiber reinforced composite panels are an attractive option for creating lightweight structures due to the tailorability for various applications and the resulting high specific properties. However, the panel stiffeners and stiffener intersections result in high tooling complexity and correspondingly high cost of implementation. These factors have limited the impact of such structures in the composites industry. Previous research has demonstrated the ability to produce high quality, high aspect ratio beams, representative of individual grid stiffeners, using E-glass/PET comingled tow via direct digital manufacturing. Further, prior preliminary efforts have demonstrated the potential to use the same approach to manufacture grid intersections that have continuous fiber in both directions. To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. Rate of deposition of the two end effectors are compared and the quality of the associated grid stiffeners, and intersections, are determined through measurement of geometry, fiber volume fraction and void fraction.
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