The automated fiber placement (AFP) process faces a crucial challenge: the emergence of out-of-plane buckling in thermoplastic prepreg tows during steering, significantly impeding the quality of composite layup. In response, this study introduces a novel approach: the development of equations for wrinkle-free fiber placement within composite pressure vessels. The investigation encompasses a detailed analysis of prepreg trajectories in relation to shell geometry, accompanied by an in-depth understanding of the underlying causes of wrinkling on dome surfaces. Moreover, a comprehensive model for shell coverage, grounded in placement parameters, is meticulously established. To validate the approach, a simulation tool is devised to calculate press roller motions, ensuring the uniform fiber dispersion on the mandrel and achieving flawless coverage of the shell without wrinkles. This innovative strategy not only optimizes the AFP process for composite layup but also remarkably enhances the overall quality of composite shells. As such, this research carries significant implications for the advancement of composite manufacturing techniques and the concurrent improvement in material performance.
Keywords: automated fiber placement; composite pressure vessel; graphic visualization; placement path planning.