Abstract: Automated fiber placement(AFP) is one of the key automated forming technologies for achieving high-quality and cost-effective manufacturing of large-scale composite components. The formation and evolution of typical defects during the automated fiber placement process, as well as the forming quality of composite structures, are influenced by the compaction force of the compaction roller. This study systematically investigates the effects of roller hardness, mold curvature(convex/concave), and placement force on pressure distribution through a combined approach of finite element simulation and pressure-sensitive film experiments, revealing the mechanism of pressure distribution for rollers with different hardness on curved surfaces. The results indicate that increasing the roller hardness reduces the contact area and increases the maximum contact pressure, enlarging the curvature radius of the mold surface improves pressure uniformity, while increasing the placement force significantly enhances distribution homogeneity. Based on the pressure uniformity and geometric constraint, a matching principle between roller length and mold curvature is proposed, providing a theoretical foundation for optimizing fiber placement parameters and suppressing typical defects such as wrinkles.

Key words: automated fiber placement, pressure distribution, curved tool, compaction roller, pressure sensitive films, finite element analysis