09:40
Session 5a: Advances in Manufacturing Automation
Chair: Sayata Ghose
09:40
20 mins
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Non-conventional strategies for manufacturing tank structures using Automated Fiber Placement
Sovit Agarwal, Dominik Delisle, Julius Biermann, Stefan Junker
Abstract: As we move closer to the 2050 climate goal of achieving net-zero carbon emissions, the aviation industry faces a challenge to rapidly develop new aircraft propulsion technologies that would align with the emission targets. Hydrogen is emerging as one of the most promising fuel alternatives which would enable aircrafts to fly with zero emissions. However, several challenges still remain before hydrogen can be used as a clean aviation fuel and one of the major ones is the development of reliable, safe and light-weight hydrogen storage technologies and its integration into the aircraft.
Research interest towards developing Type V liner-less composite tanks has significantly increased, especially for commercial aviation because of its huge advantage in weight reduction when compared to tanks with metal / plastic liners. Therefore, the main objective of this research is to advance the manufacturing technology and methodology required to produce Type V CFRP tank structure using Automated Fiber Placement (AFP) technique. The research focuses on challenges faced when conventional AFP manufacturing methodologies and strategies, that are mostly used for flat or slightly curved surfaces, are applied to rotational bodies like a tank structure and attempts to provide new solutions to overcome these challenges.
AFP-related parameter settings such as layup strategy, staggering of consecutive plies and starting & cutting sequences were studied as these parameters directly influence the degree of coverage, gap overlaps and layup quality respectively. CAM simulations and experimental trials were performed to compare the conventional tape placement strategies with the newly proposed strategies and it was found that the new strategies improved the overall degree of coverage, gap distribution and layup quality significantly, especially in the spherical region of the tank structure where steering of the material by the AFP head causes majority of the problems. A detailed quantitative and qualitative discussion on the major drawbacks associated with conventional tape placement strategies and the advantages of the newly proposed strategies will be presented in the full paper.
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10:00
20 mins
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Hybrid Robotic Winding with Integrated Multi-Material Application: A Unified Software–Hardware Approach for Advanced Composite Manufacturing
Soren Blomaard, Rob Barendse
Abstract: Hybrid Robotic Winding with Integrated Multi-Material Application: A Unified Software–Hardware Approach for Advanced Composite Manufacturing
This work describes a hybrid manufacturing cell that integrates filament winding (FW) and automated fiber placement (AFP) to enable multi-material layups on a single robotic platform governed by one CAD/CAM workflow. A robotic system with automatic end-effector exchange carries both a high-speed winding tool and an AFP head, operating with a synchronized rotary mandrel. This shared kinematic chain eliminates inter-cell part transfers and maintains a single coordinate frame across processes.
The software treats FW and AFP as peer operations defined directly on the part geometry. Within a single project, users specify filament winding layers and localized reinforcements; the system then compiles collision-aware toolpaths and head-swap transitions into a single controller program. Offline simulation validates reachability and clearance for both tools and provides cycle-time estimates. High-fidelity FE models can be exported directly to finite-element solvers to support pre-manufacture analysis and optimization.
Multi-material application is supported through modular process toolboxes in the CAD/CAM software, coupled with a flexible robotic system that can be extended with different end-effectors using tool stations with automatic tool changers. The unified environment coordinates inter-process sequencing between FW and AFP, and other processes like rubber winding or milling processes.
The integration of multiple processes into the same workstation, reduces floor space and avoids re-fixturing. The unified software approach offers new design opportunities for engineers combining multiple materials and processes within a single software environment. Representative applications include pressure vessels and cylindrical fuselage sections requiring rapid baseline winding with locally tailored AFP reinforcements. Overall, the combined software–hardware stack provides a practical route to manufacturable, functionally graded laminates with controlled quality and traceability.
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