Development of Composite Tape Laying Process for Advanced Fibrous Reinforced Composite Structures

摘要

The objective of the research was to develop and fabricate a numerically controlled prototype tape laying machine for performing layup operations required by airframe structural components of filament reinforced resin matrix composites. Mechanical functions of the machine as related to airframe component design requirements were investigated and defined. These included machine head variables of roller type, heat and pressure application, laying rates, tape feed mechanisms, shearing methods, disposal of cutoffs and tape specifications. In addition, compound contour requirements were considered. These included tilting vertical axis, pivot rollers, self-shaping rollers, and draping of flat layups to contour. It was determined that 75 percent of the airframe surfaces could be laid while using either the self-shaping roller or drape to shape approach, thereby eliminating the complexity factor of a 5-axis tilting head and the association of high production costs. A major problem has been tolerance control of fiber placement on the carrier. The contract has provided an improved manufacturing technology through development of an NC tape laying machine that will apply fiber reinforced tape up to 3 inches wide, to a part along a preprogrammed path. (Author)