Title: Effect of Tape Overlap on Pressure Distribution under Compaction Roller in Automated Fiber Placement

Authors: Mehdi Hojjati, Amir Hafez Yas

DOI: 10.33599/nasampe/s.25.0066

Abstract: In automated fiber placement (AFP), proper pressure distribution from the compaction roller is crucial to creating sufficient bonding between layers properly. However, certain defects can disrupt the pressure distribution. Towpreg overlap is one of the common defects, where the edge of one tape overlaps the adjacent tape, creating an uneven surface area where the roller cannot exert pressure evenly. This research investigates the influence of compaction roller stiffness and geometry on overlap handling to optimize part quality and achieve even distributed pressure. The exerted pressure from compaction rollers was evaluated using four rollers with different geometries and stiffnesses along with Finite Element Method analysis to detect each roller's pressure distribution and contact area on flat surfaces and various overlaps. The study aims to determine the ideal stiffness in both defect-free and overlap-present situations. Findings indicate that softer rollers provide greater surface coverage over overlaps but reduce pressure which can weaken the adhesion between layers, while stiffer rollers maintain higher pressure but leave large uncovered areas on uneven surfaces. The optimal stiffness range is dependent on the mold’s surface geometry, where different roller stiffness is needed for different surface geometries.

References: [1] [2] [3] [4] [5] [6] [7] S. Bhandari, R. A. Lopez-Anido, and D. J. Gardner, “Enhancing the interlayer tensile strength of 3D printed short carbon fiber reinforced PETG and PLA composites via annealing,” Addit. Manuf., vol. 30, p. 100922, Dec. 2019, doi: 10.1016/J.ADDMA.2019.100922. H. L. Tekinalp et al., “Highly oriented carbon fiber-polymer composites via additive manufacturing,” Compos. Sci. Technol., vol. 105, pp. 144–150, 2014, doi: 10.1016/j.compscitech.2014.10.009. M. Luo, X. Tian, J. Shang, W. Zhu, D. Li, and Y. Qin, “Impregnation and interlayer bonding behaviours of 3D-printed continuous carbon-fiber-reinforced poly-ether-ether- ketone composites,” Compos. Part A Appl. Sci. Manuf., vol. 121, pp. 130–138, Jun. 2019, doi: 10.1016/J.COMPOSITESA.2019.03.020. X. Gao, S. Qi, X. Kuang, Y. Su, J. Li, and D. Wang, “Fused filament fabrication of polymer materials: A review of interlayer bond,” Addit. Manuf., vol. 37, p. 101658, Jan. 2021, doi: 10.1016/J.ADDMA.2020.101658. Q. He, H. Wang, K. Fu, and L. Ye, “3D printed continuous CF/PA6 composites: Effect of microscopic voids on mechanical performance,” Compos. Sci. Technol., vol. 191, no. December 2019, p. 108077, 2020, doi: 10.1016/j.compscitech.2020.108077. M. Neitzel, R. Funck, E. Haupert, K. Friedrich, and W. Schwarz, “Filament Winding with Thermoplastic Matrices - Current Development and Equipment,” in Proceedings of the Japan International SAMPE Technical Seminar ’94 (JISTES ’94), 1994, pp. 149–168. P. A. Rodriguez and D. W. Radford, “Effect of Applied Consolidation Pressure in Direct Digital Manufacture of Continuous Fiber Reinforced Composites,” in Proceedings of the Composites and Advanced Materials Expo, September 2017, Orlando FL,USA, 2017, p. 14. [8] F. A. Ibitoye and D. W. Radford, “Experimental and statistical study on the effect of process parameters on the quality of continuous fiber composites made via additive manufacturing,” J. Thermoplast. Compos. Mater., vol. 37, no. 12, pp. 1–30, 2024, doi: 10.1177/08927057241241504. [9] F. O. Sonmez, “Modeling of the Thermoplastic Composite Tape Placement Process,” University of California, Los Angeles, 1995. [10] P. A. Rodriguez and D. W. Radford, “A DMA-Based Approach to Quality Evaluation of Digitally Manufactured Continuous Fiber-Reinforced Composites from Thermoplastic Commingled Tow,” J. Compos. Sci., vol. 6, no. 2, p. 61, 2022, doi: 10.3390/jcs6020061. [11] K. M. Warlick and D. W. Radford, “Combining aspects of additive manufacture and filament winding to produce composites with novel fiber reinforcement patterns,” CAMX 2016 - Compos. Adv. Mater. Expo, 2016. [12] S. S. Tanu, C. Brousse, and D. W. Radford, “Flexural Response and Failure Mechanisms of Digitally Manufactured Truss Core Sandwich Panels,” in Proccedings of the Composites and Advanced Materials Expo Conference, San Diego, CA September 9 – 12, 2024 , doi: 10.33599/nasampe/c.24.0345. [13] M. E. Bourgeois and D. W. Radford, “Digital Manufacture of a Continuous Fiber Reinforced Thermoplastic Matrix Truss Core Structural Panel Using Off-the-Tool Consolidation,” J. Compos. Sci., vol. 6, no. 11, 2022, doi: 10.3390/jcs6110343. [14] F. A. Ibitoye and D. W. Radford, “Additive manufacturing of sandwich panels with continuous fiber reinforced high modulus composite facings,” Polym. Compos., 2024, doi: 10.1002/pc.29196. [15] F. A. Ibitoye, and D. W. Radford, “Additive Manufacturing of Continuous Fiber Reinforced Thermoplastic Composite Grid Stiffened Panels,” in Proccedings of the American Society of Composites 39th Annual Technical Conference, San Diego, CA, October 21–23, 2024

Conference: SAMPE 2025

Publication Date: 2025/05/19

SKU: TP25-0000000066

Pages: 15

Price: $30.00