Fiber Placement Optimization for Steered-Fiber Plies
First Claim
1. A method, performed by a computer system, for determining tow cut locations for steered-fiber placement, said method comprising:
- (a) generating stream function data with a multiplicity of corresponding stream lines;
(b) generating course pair data representing successive pairs of neighboring courses having centerlines corresponding to the stream lines representing the stream function data generated in operation (a) such that there is no gap between the courses and the overlap is minimized; and
for each pair of neighboring courses;
(c) determining potential tow cut locations in areas of overlap between courses and splitting up individual tows at these locations to create tow segments,(d) generating geometry data for each potential tow cut location, and(e) selecting which tows of the pair of neighboring courses should be cut or added at which potential tow cut locations and in which direction the course should be laid down, taking a plurality of constraints into account; and
(f) generating machine code for controlling a fiber placement machine to cut tows and lay down courses in accordance with selections made in operation (e).
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Abstract
Methods for optimizing fiber placement programming for use in automated manufacture of steered-fiber composite laminates. The optimization methods are implemented in software capable of optimally translating steered-fiber laminate definitions in fiber placement code for manufacturing steered-fiber laminates without overlaps. The optimization is set up to take into account manufacturing constraints, such as minimum cut length, minimum steering radius, and fiber straightening due to steering. This software includes both geometry and optimization and will take the aforementioned issues into account by optimizing the direction of lay down and the location and sequence of cutting and adding individual tows.
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Citations
21 Claims
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1. A method, performed by a computer system, for determining tow cut locations for steered-fiber placement, said method comprising:
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(a) generating stream function data with a multiplicity of corresponding stream lines; (b) generating course pair data representing successive pairs of neighboring courses having centerlines corresponding to the stream lines representing the stream function data generated in operation (a) such that there is no gap between the courses and the overlap is minimized; and for each pair of neighboring courses; (c) determining potential tow cut locations in areas of overlap between courses and splitting up individual tows at these locations to create tow segments, (d) generating geometry data for each potential tow cut location, and (e) selecting which tows of the pair of neighboring courses should be cut or added at which potential tow cut locations and in which direction the course should be laid down, taking a plurality of constraints into account; and (f) generating machine code for controlling a fiber placement machine to cut tows and lay down courses in accordance with selections made in operation (e). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method for laying a composite ply comprising steered fibers, said method comprising:
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(a) generating stream function data with a multiplicity of corresponding stream lines; (b) generating course pair data representing successive pairs of neighboring courses having centerlines corresponding to the stream lines representing the stream function data generated in operation (a) such that there is no gap between the courses and the overlap is minimized; and for each pair of neighboring courses; (c) determining potential tow cut locations in areas of overlap between courses and splitting up individual tows at these locations to create tow segments, (d) generating geometry data for each potential tow cut location, and (e) minimizing a value of a penalty function for simulated placement of tows for one set of courses, taking into account a plurality of constraints; (f) generating machine code for controlling a fiber placement machine to cut tows and lay down courses in accordance with the results of operation (e); and (g) automatically laying down courses and cutting and adding tows in accordance with said machine code, wherein steps (a) through (f) are performed by processors. - View Dependent Claims (14, 15, 16, 17, 18)
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19. A system for designing a steered-fiber ply, comprising one or more processors programmed to execute the following operations:
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(a) generating stream function data with a multiplicity of corresponding stream lines; (b) generating course pair data representing successive pairs of neighboring courses having centerlines corresponding to the stream lines representing the stream function data generated in operation (a) such that there is no gap between the courses and the overlap is minimized; and
for each pair of neighboring courses;(c) determining potential tow cut locations in areas of overlap between courses and splitting up individual tows at these locations to create tow segments, (d) generating geometry data for each potential tow cut location, and (e) minimizing a value of a penalty function for simulated placement of tows for one set of courses, taking into account a plurality of constraints; and (f) generating machine code for controlling a fiber placement machine to cut and add tows and lay down courses in accordance with the results of operation (e). - View Dependent Claims (20, 21)
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Specification