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<p>This study tackles the problem of wall thickness nonuniformity in the automated fiber placement (AFP) of composite conical shells by introducing a layer-wise control strategy grounded in a fiber accumulation model. A mathematical model for the single-layer fiber placement path is constructed, and the equivalent area method is utilized to quantitatively describe the overlap ratio of prepreg tows, from which the axial ply thickness distribution function is derived. To achieve uniform thickness, a multi-layer placement strategy with decreasing placement heights is introduced, establishing a mapping relationship between layer termination positions and cumulative thickness. A parametric analysis reveals that achieving a target thickness of 4 mm necessitates 28 layers, with fiber placement lengths decreasing beyond the 15th layer. The optimized scheme results in a mean squared error (MSE) of 0.021 mm in the total thickness. Based on the Tsai-Wu failure criterion, the predicted ultimate internal pressure is 4.2&#xa0;MPa, slightly lower than the pre-optimization value of 4.8&#xa0;MPa. This indicates that the optimized conical shell experiences only a marginal decline in failure performance while achieving a 22.35% reduction in material usage and still satisfying the strength requirements. Finite element analysis using Abaqus shows that under an internal pressure load of 4 MPa, the maximum displacement magnitude is 4.1 × 10<sup>–2</sup> mm. This method effectively alleviates fiber accumulation induced by curvature gradients and offers a theoretical foundation for the high-precision manufacturing of thin-walled composite structures in aerospace applications.</p>

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Thickness prediction and uniformity optimization in AFP of composite conical shells via fiber accumulation modeling

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Zhiheng Wang,
  • Haojie Xu,
  • Jun Hu,
  • Zhou Yu

摘要

This study tackles the problem of wall thickness nonuniformity in the automated fiber placement (AFP) of composite conical shells by introducing a layer-wise control strategy grounded in a fiber accumulation model. A mathematical model for the single-layer fiber placement path is constructed, and the equivalent area method is utilized to quantitatively describe the overlap ratio of prepreg tows, from which the axial ply thickness distribution function is derived. To achieve uniform thickness, a multi-layer placement strategy with decreasing placement heights is introduced, establishing a mapping relationship between layer termination positions and cumulative thickness. A parametric analysis reveals that achieving a target thickness of 4 mm necessitates 28 layers, with fiber placement lengths decreasing beyond the 15th layer. The optimized scheme results in a mean squared error (MSE) of 0.021 mm in the total thickness. Based on the Tsai-Wu failure criterion, the predicted ultimate internal pressure is 4.2 MPa, slightly lower than the pre-optimization value of 4.8 MPa. This indicates that the optimized conical shell experiences only a marginal decline in failure performance while achieving a 22.35% reduction in material usage and still satisfying the strength requirements. Finite element analysis using Abaqus shows that under an internal pressure load of 4 MPa, the maximum displacement magnitude is 4.1 × 10–2 mm. This method effectively alleviates fiber accumulation induced by curvature gradients and offers a theoretical foundation for the high-precision manufacturing of thin-walled composite structures in aerospace applications.