Tool Path Optimization And Simulation For Composite Automated Fiber Placement

As typical technology of composite automated manufacturing,Automated Fiber Placement(AFP)has wide application in many fields.As one major function of CAD/CAM software,tool path optimization is able to fair tool path curve and increase manufacturing efficiency.In this paper,based on the previous researches,two optimizing algorithms are proposed,which respectively aimed at trajectory curvature and manufacturing orientation.Firstly,a tool path curvature fairing algorithm is proposed which aimed at CAD trajectory optimizing.Complex models manufacturing is the main challenge of AFP,for the sharp curvature variation change of the tool path generated based on it.And in this situation,the large curvature of tool path may introduce buckling defects to the part so as decreasing the composite part quality.To solve the problem,the relationship between buckling defects and tool path curvature is analyzed in this paper.Furthermore,a curvature fairing algorithm which tend to decrease tool path curvature is proposed and the purpose is to decrease the buckling defects during manufacturing so as to guarantee the part quality.The data analysis and placement experiment are carried out to verify the feasibility of the algorithm.On the other hand,a posture optimizing algorithm which focused on NC code is proposed.During AFP manufacturing,due to the unfairness of orientation change,servo motors are required to accelerate and decelerate frequently to meet the manufacturing orientation requirements,which limits the process rate.In order to increase the efficiency,according to the flexibility of the rubber roller,the admissible orientation domain based on the roller coordinate system is established.Furthermore,it is analyzed that rotation around different axis have different effect on the admissible domain.Under the constraint zone,the rotation curve is optimized by Butterworth digital filter and objective optimization function,which contributes to the increasement of manufacturing efficiency.The feasibility of the algorithm is proved by the data analysis and placement experiment.Finally,machine tool kinematic simulation module and trajectory dynamic display simulation module are established,which respectively simulate NC code and CAD trajectory.The mechanical link structure of typical horizontal AFP machine tool is analyzed and the kinematic module is formulated.Based on OpenGL graphics interface,the AFP machine system is created by VC++ platform.Through standard transformation function of OpenGL,the machine tool is virtual assembled and the function of multi-axis control is accomplished.The virtual machine kinematic system is able to simulate machine motion by importing NC code.On the other hand,the CAD trajectory display simulation module is established based on the format of AFP CAD trajectory.The display simulation is able to display static and dynamic simulation of central and multi tool path.The trajectory display module and the machine tool kinematic simulation constitute the basic AFP manufacturing function,which provide the optimizing algorithms proposed with basic simulation platform.