Development and Expansion of Thermoplastic AFP Process Simulations
Federica Bruno
Development and Expansion of Thermoplastic AFP Process Simulations.
Rel. Giacomo Frulla. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Aerospaziale, 2025
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Abstract
Fiber Reinforced Plastics (FRPs) are high-performance materials that combine an excellent strength-to-weight ratio, stiffness-to-weight ratio, and exceptional corrosion resistance. In the aerospace sector, FRPs are used in critical structural components such as fuselages, wings, and support elements. A key advantage of FRPs is the ability to align the load-bearing fibres along the load paths, leading to significant improvements in structural efficiency compared to traditional metallic constructions in lightweight designs. Automated Tape Placement (AFP) technology is used as an alternative to manual tape laying. The proper setup of such processes is crucial for optimal performance and configuration. This research focuses on the thermal simulation of the Thermoplastic Automated Fiber Placement (T-AFP) process, simulated in ANSYS, particularly the non-Autoclave methodology for in-situ consolidation of thermoplastic tapes to create a multi-layer composite structure.
A transient thermal analysis is performed, simulating the actual placement of tapes, which are simultaneously positioned and heated.In the first phase of the research, a method was developed to define the paths on the surface of a tool flat panel, based on its geometric characteristics, the orientation angle, the of the lay-up strategy, and the dimensions of the tapes
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