On the use of PGD for optimal control applied to automated fibre placement

Automated Fibre Placement (AFP) is an incipient manufacturing process for composite structures. Despite its concep-tual simplicity it involves many complexities related to the necessity of melting the thermoplastic at the interface tape-substrate, ensuring the consolidation that needs the diffusion of molecules and control the residual stresses installation responsible of the residual deformations of the formed parts.The optimisation of the process and the determination of the process window cannot be achieved in a traditional way since it requires a plethora of trials/errors or numerical simulations, because there are many parameters involved in the characterisation of the material and the process.Using reduced order modelling such as the so called Proper Generalised Decomposition method, allows the construction of multi-parametric solution taking into account many parameters. This leads to virtual charts that can be explored on-line in real time in order to perform process optimisation or on-line simulation-based control. Thus, for a given set of parameters, determining the power leading to an optimal temperature becomes easy.However, instead of controlling the power knowing the temperature field by particularizing an abacus, we propose here an approach based on optimal control: we solve by PGD a dual problem from heat equation and optimality criteria. To circumvent numerical issue due to ill-conditioned system, we propose an algorithm based on Uzawa’s method. That way, we are able to solve the dual problem, setting the desired state as an extra-coordinate in the PGD framework. In a single computation, we get both the temperature field and the required heat flux to reach a parametric optimal temperature on a given zone.