基于约束触发与遗传搜索的复合材料自动铺丝分区方法

A partitioning method for automated fiber placement of composite materials based on constraint triggering and genetic search

  • 摘要: 针对碳纤维增强树脂基复合材料复杂曲面自动铺丝中偏移路径易出现转弯半径不足、角度偏差超限及分区边界衔接不稳定的问题,提出一种基于约束触发与遗传算法的分区方法。采用曲率筛选、最远点采样和覆盖率择优确定初始种子点;以转弯半径和角度偏差作为可铺放性约束,在路径偏移过程中判定分区边界;将新分区种子点选取转化为已有边界曲线上的一维参数优化问题,并结合遗传算法和偏移距离优化确定种子点位置;建立基于三角网格曲面采样的碳纤维预浸料丝束覆盖率、重叠率和间隙率计算方法,实现分区铺放质量评价。以机翼曲面和半进气道曲面模型为算例进行验证,结果表明,所提方法在不同铺层角度下均能够生成连续、稳定的分区铺放路径。相比扇形分区方法,平均分区数量由8.63个降至3.88个,平均覆盖率提高至99.15%,平均重叠率和平均间隙率分别降至0.36%和0.49%。结果表明,所提方法能够有效减少分区数量,降低重叠与间隙比例,从而提高复杂曲面自动铺丝分区质量。

     

    Abstract: To address insufficient turning radius, excessive angle deviation, and unstable boundary connections between partitions in offset paths during automated fiber placement of carbon fiber reinforced resin matrix composites on complex surfaces, a partitioning method based on constraint triggering and genetic algorithm is proposed. The initial seed points are determined through curvature screening, farthest point sampling, and coverage-based selection. The turning radius and angle deviation are introduced as placement feasibility constraints to identify partition boundaries during path offsetting. The selection of seed points for new partitions is transformed into a one-dimensional parametric optimization problem along existing boundary curves, and the seed point positions are optimized by combining genetic algorithm search with offset distance optimization. Furthermore, a calculation method for evaluating the coverage rate, overlap rate, and gap rate of carbon fiber prepreg tows is established based on triangular mesh surface sampling, enabling quantitative assessment of partition placement quality.A wing surface model and a half-inlet surface model are employed for verification. The results demonstrate that the proposed method can generate continuous and stable partitioning paths under different ply angles. Compared with the sector-based partitioning method, the average number of partitions is reduced from 8.63 to 3.88, the average coverage rate is increased to 99.15%, and the average overlap rate and gap rate are reduced to 0.36% and 0.49%, respectively. The proposed method effectively reduces the number of partitions and decreases overlap and gap defects, thereby improving the partitioning quality of automated fiber placement on complex surfaces.

     

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