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Evaluation of control methods for thermal roll forming of aerospace composite materials

Land, Patrick; De Sousa, Luis; Ratchev, Svetan; Branson, David T.; Brookes, Harvey; Wright, Jon

Authors

LISA PATRICK LISA.PATRICK2@NOTTINGHAM.AC.UK
Research Occupational Therapist

Luis De Sousa

Professor SVETAN RATCHEV svetan.ratchev@nottingham.ac.uk
Cripps Professor of Production Engineering & Head of Research Division

David T. Branson

Harvey Brookes

Jon Wright



Abstract

With increased demand for composite materials in the aerospace sector there is a requirement for the development of manufacturing processes that enable larger and more complex geometries, whilst ensuring that the functionality and specific properties of the component are maintained. To achieve this, methods such as thermal roll forming are being considered. This method is relatively new to composite forming in the aerospace field, and as such there are currently issues with the formation of part defects during manufacture. Previous work has shown that precise control of the force applied to the composite surface during forming has the potential to prevent the formation of wrinkle defects. In this paper the development of various control strategies that can robustly adapt to different complex geometries are presented and compared within simulated and small scale experimental environments, on varying surface profiles. Results have found that traditional PID control can be utilized, although its robustness under varying conditions reduces performance in situations that are far from the tuned scenario. This causes the PID controller to struggle with geometries containing surfaces with high frequency surface variations. To enable more robust control an H∞ based controller was therefore developed for the thermal roll forming process. Simulated results show that while the individual implementation of both controllers were successful in achieving the desired response, the H∞ based controller was able to perform better across a wider range of desired surface profiles.

Journal Article Type Article
Publication Date Dec 1, 2016
Journal SAE International Journal of Aerospace
Electronic ISSN 1946-3901
Publisher SAE International
Peer Reviewed Peer Reviewed
Volume 9
Issue 2
APA6 Citation Land, P., De Sousa, L., Ratchev, S., Branson, D. T., Brookes, H., & Wright, J. (2016). Evaluation of control methods for thermal roll forming of aerospace composite materials. SAE International Journal of Aerospace, 9(2), https://doi.org/10.4271/2016-01-2118
DOI https://doi.org/10.4271/2016-01-2118
Publisher URL http://papers.sae.org/2016-01-2118/
Copyright Statement Copyright information regarding this work can be found at the following address: http://eprints.nottingh.../end_user_agreement.pdf

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Copyright Statement
Copyright information regarding this work can be found at the following address: http://eprints.nottingham.ac.uk/end_user_agreement.pdf





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