Spreading modeling of prepreg tape used for manufacturing of variable angle tow composites

Abstract Variable angle tow (VAT) laminates are gaining popularity for enhancing composite structure performance. Automated fiber placement (AFP) is an effective method for tailoring VAT laminates to boost manufacturing efficiency. However, traditional AFP equipment faces limitations, such as the inability to eliminate defects like gaps and overlaps due to a minimum steering radius. This study addresses these defects by examining the spreading behavior of prepreg tapes. A simplified Navier-Stokes equation-based model is developed to analyze the impact of pressure and temperature on tape spreading width. Experimental validation, conducted under conditions that simulate automated layup operations, demonstrated that the tapes can be significantly broadened by up to 30% with increased temperature and pressure. The experimental data is curve-fitted using the least square method, and the model shows a good fit with the results.