Dynamic frictional slip behavior of unidirectional thermosetting prepregs during automated fiber placement

Authors:
  • SJShaomeng Jin
    Shaomeng Jin
  • YZYuchen Zhang
    Yuchen Zhang
  • DPDenis J. Politis
    Denis J. Politis
  • ZKZbigniew L. Kowalewski
    Zbigniew L. Kowalewski
  • XLXiaochuan Liu
    Xiaochuan Liu
  • YDYugang Duan
    Yugang Duan
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Abstract
Tangential interfacial slip behavior of unidirectional (UD) uncured thermosetting prepregs is a critical state-dependent phenomenon in Automated Fiber Placement (AFP). Tangential slip at prepreg-prepreg (P/P) and prepreg-tool (P/T) interfaces directly affects tow steering capability, initiation and propagation of defects (such as wrinkles and tow deviation), which further affects the microstructure, stress distribution, strength, and for aerospace applications the aerodynamic performance of the part. However, there remains significant room for improvement in characterizing multi-variable tangential slip, especially for studying and understanding transient yield-like and orientation-dependent behaviors. The present study experimentally investigates and models these behaviors of the P/P and P/T interface at different interfacial ply angles, compaction pressures and temperatures. A device capable of measuring the interlaminar slip characteristics of prepregs at any interfacial angle was designed, and experimentally tested, with data analysis and microstructural analysis subsequently conducted on T800/AC531 aerospace prepregs. Based on the slip mechanism characteristics, a phenomenological two-channel model was developed to characterize the evolution of the slip force as slippage progressed. Following calibration, the model demonstrates high-fidelity agreement with experimental data. By incorporating multiple experimental factors such as temperature, pressure, and orientation, the model accurately replicated the slip history (for P/P contact and for P/T contact), providing a reliable mathematical model for AFP process simulation and optimization.

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