Nicolas Bur

On the use of model order reduction for simulating automated fibre placement processes

Automated fibre placement (AFP) is an incipient manufacturing process for composite structures. Despite its conceptual simplicity it involves many complexities related to the necessity of melting the thermoplastic at the interface tape-substrate, ensuring the consolidation that needs the diffusion of molecules and control the residual stresses installation responsible of the residual deformations of the formed parts. The optimisation of the process and the determination of the process window requires a plethora of simulations because there are many parameters involved in the characterization of the material and the process. The exploration of the design space cannot be envisaged by using standard simulation techniques. In this paper we propose the off-line calculation of rich parametric solutions that can be then explored on-line in real time in order to perform inverse analysis, process optimisation or on-line simulation-based control. In particular, in the present work, and in continuity with our former works, we consider two main extra-parameters, the first related to the line acceleration and the second to the number of plies laid-up.