Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters
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ORIGINAL ARTICLE
Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters ´ 1 Omar Baho1 · Gilles Ausias1 · Yves Grohens1 · Julien Ferec Received: 3 December 2019 / Accepted: 5 August 2020 / Published online: 2 September 2020 © The Author(s) 2020
Abstract Laser-assisted automated fiber placement (AFP) is highly suitable for an efficient production of thermoplastic-matrix composite parts, especially for aeronautic/aerospace applications. Heat input by laser heating provides many advantages such as better temperature controls and uniform heating projections. However, this laser beam distribution can be affected by the AFP head system, mainly at the roller level. In this paper, a new optico-thermal model is established to evaluate the laser energy quantity absorbed by a poly(ether ether ketone) reinforced with carbon fibers (APC-2). During the simulation process, the illuminated radiative material properties are characterized and evaluated in terms of the roller deformation, the tilt of the robot head, and the reflection phenomenon between the substrate and the incoming tape. After computing the radiative source term using a ray-tracing method, these data are used to predict the temperature distribution on both heated surfaces of the composite during the process. The results show that both the roller deformation and the tilt of head make it possible to focus the laser beam on a small area, which considerably affects the quality of the finished part. These findings demonstrate that this optico-thermal model can be used to predict numerically the insufficient heating area and thermoplastic composites heating law. Keywords Automated fiber placement · Laser heating · Ray tracing · Thermoplastic composite · Optico-thermal analysis
1 Introduction Continuous fiber reinforced thermoplastic polymer composites aim to exhibit superior properties like mechanical performance and the potential for lightweight structures. Its likely recyclability makes it a good choice for many applications, especially for aeronautic/aerospace parts. Thermoplastic-based composites allow shorter processing cycle and are also characterized by their high glass transition temperatures compared with thermosets. They have the possibility to be processed through fusion bonding which involves the application of heat and pressure at the interface [1], and therefore can be processed quickly in situ without using autoclaves [2]. Nowadays, these composites are used in a wide range of high-performance structure applications [3], and high-quality parts are produced thanks
Julien F´erec
[email protected] 1
UMR CNRS 6027, IRDL, Universit´e Bretagne Sud, F-56100, Lorient, France
to improvements in processing technology, more especially concerning the radiation heating [4]. For instance, the automated fiber placement (AFP) allows manufacturing composite materials out of autoclave. The AFP lays the prepreg material over flat or curved surfaces with a robotic placement head. The surfaces of both the tape and th
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