Modelling the Heating Process in the Transient and Steady State of an In Situ Tape-Laying Machine Head

Abstract

As the use of composite materials increases, the search for suitable automated processes gains relevance for guaranteeing production quality by ensuring the uniformity of the process, minimizing the amount of scrap generated, and reducing the time and energy consumption. Limitations on production by traditional means such as hand lay-up, vacuum bagging, and in-autoclave methods tend not to be as efficient when the size and shape complexity of the part being produced increases, motivating the search for alternative processes such as automated tape laying (ATL). This work aims to describe the process of modelling and simulating a composite ATL with in situ consolidation by characterizing the machine elements and using the finite differences method in conjunction with energy balances in order to create a digital twin of the process for further control design. The modelling approach implemented is able to follow the process dynamics when changes are made to the heating element and to predict the composite material temperature response, making it suitable for use as a digital twin of a production process using an ATL machine.

Keywords

• automatic fiber laying
• thermoplastic composites
• process simulation
• digital twin