Evaluation of robotic fiber placement effect on process‐induced residual stresses using incremental hole‐drilling method

Abstract The robotic fiber placement (RFP) process depends on continuous fusion bonding and solidifying of prepreg tows onto a substrate by subjecting them to a compression force and heat flux. However the advantages provided when using the RFP to fabricate the composite structures, it has adverse effects due to the induced residual stresses (RSs). The current work presents the effect of the RFP on the induced RSs in thermoset composites. RFP is utilized to fabricate specimens from carbon fiber reinforced polymers. Effects of placement speed, compression force, heating temperature, heating gas flowrate, and the location of the heat flux outlet nozzle are all included in the present study. A total of 69 flat panels are manufactured under different process conditions. Subsequently, the in‐depth RSs are measured using the incremental hole‐drilling method. Besides, the microstructures of the samples are also analyzed. The results show that the change in process parameters could significantly affect the induced RSs of the thermoset composites. Subjecting the samples to higher thermal and pressure loads would induce more RSs, which are attributed to the occurrence of partial curing during the manufacturing process along with the change in laminate geometry and porosity.