Introduction
Composite manufacturing has seen tremendous advancements in the past few decades with the introduction of automated fiber placement (AFP) and automated tape laying (ATL) machines. These machines have significantly improved production rates and part quality compared to traditional hand layup processes.
Automated Fiber Placement
Automated fiber placement (AFP) involves the precise placement of composite fibers or fiber tapes onto a mold surface under computer numerical control (CNC). An AFP machine consists of a creel that houses composite spools, a fiber placement head and a mold mounted on a multi-axis gantry system. The fiber placement head can maneuver in multiple directions and places the fibers onto the mold at high speeds with great precision.
The mold surface follows a predefined toolpath and fibers are deposited onto it layer by layer. Each layer can have different fiber orientations to impart desired strength properties. AFP allows placing fibers in almost any geometrically complex shapes. Complex curved parts with double curvatures can be manufactured using AFP which would be impossible with traditional hand layup. The machine ensures uniform fiber distribution, minimal fiber breaks and wrinkle-free layup. This results in high strength and repeatability of the manufactured parts.
Automated Tape Laying
While Automated Fiber Placements And Automated Tape Laying Machines places individual fibers, automated tape laying (ATL) involves the placement of continuous composite tapes onto the mold surface. ATL machines have spools of composite prepreg tapes instead of individual fibers. The tape laying head picks the tape from the spool and places it on the mold with the help of dynamically controlled roller and heater systems. Proper roller pressure and heating maintains tape tack and adheres it firmly on the mold surface.
Similar to AFP, ATL also follows predefined toolpaths to lay tape in multiple orientations layer over layer. Automated compaction rollers apply uniform pressure on the laid tapes to consolidate the laminate. ATL eliminates issues like fiber waviness and minimizes voids in the laminate. It provides excellent in-plane properties and repeatability. ATL can manufacture large, flat composite parts very quickly with consistent quality.
Applications
AFP and ATL technologies are revolutionizing manufacturing across many industries like aerospace, automotive, marine etc. Major applications include:
Aerospace: AFP/ATL are primarily used to make fuselage panels, wing skins, empennages and other complex composite structures for commercial and military aircrafts. They help achieve immense weight savings over metallic parts.
Automotive: Composite parts made using AFP/ATL are gaining popularity in high-end cars. Components like hoods, roof panels, trunk lids are being replaced by lighter composites.
Wind turbine: Blades of wind turbines are usually made of glass or carbon fiber composites. ATL is well-suited to manufacture large blade shells efficiently.
Shipping: Use of composites in shipbuilding has increased massively. Complex hull and superstructure parts are made using AFP and ATL to achieve weight reduction.
Future Scope and Challenges
As composites penetrate new industries and applications, demand for AFP and ATL machines will continue rising in future. Ongoing R&D is focused on enhancing machine speeds, widths, level of automation and material compatibility. Other evolutions include multi-axis hybrid machines for combined AFP/ATL, automation of material delivery and in-process quality monitoring.
While the technologies have come a long way, high initial costs of AFP/ATL equipment remains a hurdle for wider adoption, especially in low-volume sectors. Integration challenges with existing production workflows is another factor slowing penetration. Recent efforts aim to make machines more affordable, modular and easily configurable for SMEs. Continued cost reductions through design innovations will be key to mainstream their use.
Automated fiber placement and automated tape laying have revolutionized large-scale composite manufacturing. They present a scalable, flexible and robust solution for intricate aerospace, automotive and industrial applications. With persistent R&D and falling costs, composites are poised to displace more metals. AFP and ATL will continue powerinsg this paradigm shift by enabling mass-production of parts with unprecedented strength-to-weight ratios.
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