Optimization of Laser-Assisted Tape Winding/Placement Process using Inverse Optical Model

Frank Sebastiaan Esselink, Seyed Mohammad Amin Hosseini*, Ismet Baran, Remko Akkerman

*Corresponding author for this work

Research output: Contribution to journalConference articleAcademicpeer-review

2 Citations (Scopus)
27 Downloads (Pure)

Abstract

Laser-assisted tape winding/placement (LATW/P) is a process in which fiber-reinforced thermoplastic prepregs are heated by a laser source and in-situ consolidated by a compaction roller. Maintaining a constant temperature along the prepreg width prior to the nip point is utmost necessary to manufacture fiber-reinforced thermoplastic composites with proper bonding quality. The heat flux distribution on the incoming prepreg tape and already placed substrate is affected by the local geometry and variation in process parameters during the process. In order to maintain the processing temperature distribution at the desired conditions, a new process optimization approach for the laser power distribution is presented. A laser source with variable power distribution is considered in the optimization scheme which can improve the bonding quality of the final product by achieving the desired constant nip point temperature distribution. The variable laser power distribution can be realized practically with the Vertical-Cavity Surface-Emitting Laser (VCSEL) technology. An inverse optical and thermal process models are developed in which an ideal laser power distribution is calculated based on the surface temperature distributions on the tape and substrate described as an input to the process model. Two different optimization studies are performed based on two different input temperature profiles namely stepwise and linearly ramp profile. First, the inverse thermal model is used to calculate the required heat flux distribution which is forwarded as an input to the inverse optical model. The obtained heat flux distribution is transformed into the laser power distribution using the optical model in which the ray-tracing method is used. The relation between the surface temperature distribution and laser power distribution is investigated. The obtained laser power distribution using the inverse optical model is compared with the calculated laser power distribution as an input for the already developed optical-thermal model.

Original languageEnglish
Pages (from-to)182-189
Number of pages8
JournalProcedia manufacturing
Volume47
DOIs
Publication statusPublished - 26 Apr 2020
Event23rd International Conference on Material Forming, ESAFORM 2020 - BTU Cottbus-Senftenberg, Cottbus, Germany
Duration: 4 May 20206 May 2020
Conference number: 23
https://esaform2020.org/

Keywords

  • Inverse modelling
  • Laser-assisted tape placement
  • Process modelling
  • VCSEL
  • Winding

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