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In laminate composite structure design, it is common to deal with the need of varying thickness to reach project requirement or improve performance. This change of thickness can be achieved by terminating or adding plies at different locations over the laminate. Unfortunately, the inherent weakness of this construction is the presence of material and geometric discontinuities at the ply drop region that induce premature interlaminar failure at interfaces between dropped and continuous plies.

In this work, tensile strength tests were performed on tapered laminates with internal ply drop-off using digital image correlation (DIC) technique. The laminate based on a new thermoplastic ELIUM® 150 reinforced by a plain weave carbon fabric was manufactured via VARTM. Stress, strain, displacement and tensile strength were analyzed. A 3D finite element analysis (FEA) and design of experiments (DOEs) were carried out for the analysis of effect of position and angle orientation of dropped plies near the thinner section of the tapered laminate. Tsai Wu's criterion was implemented to predict initiation of first ply failure.

Numerical and experimental results showed that position and angle orientation of ply drop-off near the thinner thickness influence tensile strength of tapered laminate. Tensile static strength increases 12% when drop-off near the midplane is oriented at ±45° instead of 0°. Results showed a trend of improvement in the tensile strength when drop-off is positioned over midplane of the laminate composite. Results obtained through the DOEs were able to adjust the metamodel according to a linear model with great efficiency. They show the significant relevance of the manufacturing variables and the interaction between the factors.

The present work aims to evaluate the effect of ply drop-off on the strength of carbon fiber thermoplastic composite laminates with internal drop-off under tensile load and propose a design guideline about angle orientation and position of dropped plies closer to the thinner section of the laminate.

This paper deals with the optimum design of composite laminated plates. Both ply orientation angles and ply thicknesses of the composite plate are used as design variables. The optimum design process is divided into two sublevels. In the first sublevel, the strain energy of the plate is minimized by changing the ply orientation angles while the ply thickness distributions remain unmodified. In the second sublevel, with the angle values obtained in the first sublevel, the optimum thickness distribution of each ply is obtained by minimizing the structural weight while satisfying stiffness and gauge constraints. The final optimum design is achieved by iterating between these two sublevels. The stiffness analysis is performed by the finite element method in which a triangular element is used that is suitable for from thin to thick plates and includes the transverse shear effects. All the derivative analysis is performed analytically. The mathematical programming method called Constrained Variable Metric is used to solve the optimum problem. An example is provided for a rectangular laminated plate with good results to show the effectiveness of the method.

The purpose of this paper is to demonstrate new design concepts for 24 classes of laminate, which have been derived as part of an ongoing study on the development of a unified approach to the characterization of coupled laminates. The paper presents a description of each class of coupled laminate.

The paper gives an overview of the desired performance and requirements of a smart leading edge device, its aerodynamic design for the wind tunnel tests and the structural pre‐design and sizing of the full‐scale leading edge section which will be tested in the wind tunnel.

Coupled laminates have potential applications in the design of aero‐elastic compliant rotor blades or aircraft wing structures, by introducing tailored extension‐twist and/or shear‐extension coupling at the laminate level; or in the design of thermally activated morphing structures, by exploiting more complex coupling behaviour.

These laminates contain standard cross‐ply and/or angle‐ply combinations, although double angle‐ply laminates are also considered, and correspond to any standard fibre/matrix system with a constant ply thickness throughout.

The vast majority of the laminate described possess coupling behaviour not previously identified in the literature.

Many studies only take into account the ply stacking sequence as the design variable to determine the optimal ply drop-off location; however, it is necessary to optimize other parameters that have a direct influence on the ply drop-off site such as which plies should be dropped and in which longitudinal direction. That way, the purpose of this study is to find the most significant design variables relative to the drop-off location considering the transversal and longitudinal positions, seeking to achieve the optimal combination of ply drop-off locations that provides excellent performance for the laminate plate.

This study aims to determine the optimal drop-off location in a laminate plate using the finite element method and an approach statistical with design of experiments (DOE).

The optimization strategy using DOE revealed to be satisfactory for analyzing laminate structures with ply drop-offs, demonstrating that not all design factors influence the response variability. The failure criterion response variable revealed a poor fit, with an adjusted coefficient of determination lower than 60%, thus demonstrating that the response did not vary with the ply drop-off location. Already the strain and natural frequency response variables presented high significance. Finally, the optimization strategy revealed that the optimal drop-off location that minimizes the strain and maximizes the natural frequency is the ply drop-off located of the end plate.

It was also noted that many researchers prefer evolutionary algorithms for optimizing composite structures with ply drop-offs, being scarce to the literature studies involving optimization strategies using response surface methodology. In addition, many studies only take into account the ply stacking sequence as the design variable to determine the optimal ply drop-off location; however, in this study, the authors investigated other important parameters that have direct influence on the ply drop-off site such as which plies should be dropped and in which longitudinal direction.

Presents a finite element formulation of the layout optimization and design sensitivity applied to doubly‐curved shells of revolution. The objectives of the optimization are to maximize buckling pressures and first‐ply‐failure pressures. The problem is formulated and solved with the use of geometrically non‐linear transverse shear shell theory. However, the optimization method proposed limits the sensitivity analysis to a geometrically linear problem. Focuses special attention on the formulation of the optimization problem taking into account various factors, such as the form of geometrical and physical relations, types of design variables and the finite element discretization. Demonstrates several numerical examples to illustrate the capability of the proposed optimization procedures.

The purpose of this paper is to investigate the mechanical properties’ behaviors of woven composite cut-out structures with specific parameters. Because of the complexity of micro-scale and meso-scale structure, it is difficult to accurately predict the mechanical material behavior of woven composites. Numerical simulations are increasingly necessary for the design and optimization of test procedures for composite structures made by the woven composite. The results of the proposed method are well satisfied with the results obtained from the experiment and other studies. Moreover, parametric studies on different plates based on the stacking sequences are investigated.

A multi-scale modeling approach is suggested. Back-propagation neural networks (BPNN), radial basis function (RBF) and least square support vector regression are integrated with efficient global optimization (EGO) to reduce the weight of assigned structure. Optimization results are verified by finite element analysis.

Compared with other similar studies, the advantage of the suggested strategy uses homogenized properties behaviors with more complex analysis of woven composite structures. According to investigation results, it can be found that 450/−450 ply-orientation is the best buckling load value for all the cut-out shape requirements. According to the optimal results, the BPNN-EGO is the best candidate for the EGO to optimize the woven composite structures.

A multi-scale approach is used to investigate the mechanical properties of a complex woven composite material architecture. Buckling of different cut-out shapes with the same area is surveyed. According to investigation, 45°/−45° ply-orientation is the best for all cut-out shapes. Different surrogate models are integrated in EGO for optimization. The BPNN surrogate model is the best choice for EGO to optimization difficult problems of woven composite materials.

This paper aims to focus on calculating the number of layers of composite laminates required to take the applied load made up of graphite/epoxy (AS4/3501-6) which can be used in many industrial applications. Optimization for minimization of weight by variation in the mechanical properties is possible by using different combinations of fiber angle, number of plies and their stacking sequence.

Lots of research studies have been put forth by aerospace industry experts to improve the performance of aircraft wings with weight constraints. The orthotropic nature of the laminated composites and their ability to characterize as per various performance requirements of aerospace industry make them the most suitable material. This leads to necessity of implementing most appropriate optimization technique for selecting appropriate parameter sets and material configurations.

In this work, exhaustive enumeration algorithm has been applied for weight minimization of fiber laminated composite beam subjected to two different loading conditions by computing overall possible stacking sequences and material properties using classical laminate theory. This combinatorial type optimization technique enumerates all possible solutions with an assurance of getting global optimum solution. Stacking sequences are filtered through Tsai-Wu failure criteria.

Finally, through the outcome of this optimization framework, eight different combinations of stacking sequences and 24-ply symmetric layup have been obtained. Furthermore, this 24-ply layup weighing 0.468 kg has been validated using finite element solver for given boundary conditions. Interlaminar stresses at top and bottom of the optimized ply layup were validated with Autodesk’s Helius composites solver.

A conceptual design method for composite material stiffened panels used in aircraft tail structures and unmanned aircraft has been developed to bear compression and shear loads.

The method is based on classical laminated theory to fulfil the requirement of building a fast design tool, necessary for this preliminary stage. The design criterion is local and global buckling happen at the same time. In addition, it is considered that the panel does not fail due to crippling, stiffeners column buckling or other manufacturing restrictions. The final geometry is determined by minimising the area and, consequently, the weight of the panel.

The results obtained are compared with a classical method for sizing stiffened panels in aluminium. The weight prediction is validated by weight reductions in aircraft structures when comparing composite and aluminium alloys.

The work is framed in conceptual design field, so hypotheses like material or stiffeners geometry shall be taken a priori. These hypotheses can be modified if it is necessary, but even so, the methodology continues being applicable.

The procedure presented in this paper allows designers to know composite structure weight of aircraft tails in commercial aviation or any lifting surface in unmanned aircraft field, even for unconventional configurations, in early stages of the design, which is an aid for them.

The contribution of this paper is the development of a new rapid methodology for conceptual design of composite panels and the feasible application to aircraft tails and also to unmanned aircraft.

The purpose of this study is to enable performing reliability-based design optimisation (RBDO) for a composite component while accounting for several multi-scale uncertainties using a large representative volume element (LRVE). This is achieved using an efficient finite element analysis (FEA)-based multi-scale reliability framework and sequential optimisation strategy.

An efficient FEA-based multi-scale reliability framework used in this study is extended and combined with a proposed sequential optimisation strategy to produce an efficient, flexible and accurate RBDO framework for fibre-reinforced composite laminate components. The proposed RBDO strategy is demonstrated by finding the optimum design solution for a composite component under the effect of multi-scale uncertainties while meeting a specific stiffness reliability requirement. Performing this using the double-loop approach is computationally expensive because of the number of uncertainties and function evaluations required to assess the reliability. Thus, a sequential optimisation concept is proposed, which starts by finding a deterministic optimum solution, then assesses the reliability and shifts the constraint limit to a safer region. This is repeated until the desired level of reliability is reached. This is followed by a final probabilistic optimisation to reduce the mass further and meet the desired level of stiffness reliability. In addition, the proposed framework uses several surrogate models to replace expensive FE function evaluations during optimisation and reliability analysis. The numerical example is also used to investigate the effect of using different sizes of LRVEs, compared with a single RVE. In future work, other problem-dependent surrogates such as Kriging will be used to allow predicting lower probability of failures with high accuracy.

The integration of the developed multi-scale reliability framework with the sequential RBDO optimisation strategy is proven computationally feasible, and it is shown that the use of LRVEs leads to less conservative designs compared with the use of single RVE, i.e. up to 3.5% weight reduction in the case of the 1 × 1 RVE optimised component. This is because the LRVE provides a representation of the spatial variability of uncertainties in a composite material while capturing a wider range of uncertainties at each iteration.

Fibre-reinforced composite laminate components designed using reliability and optimisation have been investigated before. Still, they have not previously been combined in a comprehensive multi-scale RBDO. Therefore, this study combines the probabilistic framework with an optimisation strategy to perform multi-scale RBDO and demonstrates its feasibility and efficiency for an fibre reinforced polymer component design.

The purpose of this paper is to present a skin-based approach able to generate the variability model for a component in composite material due to its manufacturing process. It generates a skin-based model of the manufactured part. The skin model discretizes the part surfaces by points to take into account the geometric deviations, those points are the nodes of finite element analysis used for tolerance analysis of compliant assemblies.

The paper presents a general and systematic simulation model for generating a variability meta-model for a component in composite material due to its manufacturing process. The model is constituted by three steps: definition and pre-processing of the nominal model, generation of the manufacturing process model and evaluation of the part variability.

The advantage of this approach is related to the fact that it is designed as a part of a digital process that establishes a continuous and unambiguous flow of variation information from the part design to manufacturing and assembly and that takes into account the manufacturing signature. This is its uniqueness compared to other simulation approaches focused only on manufacturing.

Considering the variability around the nominal value of all the process parameters and parts with more complex geometries are not taken into account now, which will be modelled in practical applications.

To properly manage uncertainty since conceptual design of complex product, next generation geometry assurance requires simulation models to realistically consider process signatures due to the manufacturing process. This work focusses on this next generation tool for geometry assurance.

The literature is focused on metal sheets joined by welding or riveting. There are other materials widely used and typically compliant: the composite materials that typically used mechanical fixing elements (bolting, riveting) and structural adhesives to joint parts. No software tools exist in the literature to deal with uncertainty from manufacturing to assembly processes in products made by composite. This is the reason of the present work.