Method for analyzing toe lay-up design of one-piece composite structure with closed end geometry

Abstract

To provide a method for analyzing toe lay-up designs of one-piece composite structures with closed end geometries.SOLUTION: A method includes steps of: receiving, from a design data file repository via a communications network and a network interface, a design data file for a toe lay-up design of a one-piece composite structure with closed end geometries to a computing device (102); processing, with the computing device, the design data file to construct a three-dimensional model of the one-piece composite structure (104); analyzing, with at least one computing device, the three-dimensional model to evaluate modulus characteristics of the toe lay-up design (106); and generating, with the computing device, modulus result data reflecting the modulus characteristics of the toe lay-up design of the one-piece composite structure based on the analysis of the three-dimensional model (108).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001]

[0001] The present disclosure relates generally to techniques for analyzing tow layup designs, and more particularly to techniques for analyzing designs of one-piece composite structures having closed end shapes. Various techniques include analyzing a three-dimensional model of the one-piece composite structure based on the tow layup design. The one-piece composite structure may also include an elongated hollow body. For example, the closed end shape may include a dome. Other shapes of the closed end are also contemplated. The elongated hollow body may include a cylinder. Other shapes of the elongated hollow body are also contemplated. The elongated hollow body and the closed end shape are joined at a transition region. [Background technology]

[0002]

[0002] Current designs of composite structures containing cylinders and integral domes use sequentially terminating scarves that restrict the placement of the dome fibers, resulting in large variations in modulus and "soft spots" (i.e., low Ex).

[0003]

[0003] Accordingly, those skilled in the art continue to engage in research and development efforts to improve techniques for analyzing the design of one-piece composite structures having domes. Summary of the Invention

[0004]

[0004] Several embodiments of a method for analyzing the toe layup design of a one-piece composite structure having a closed end configuration are disclosed. The following is a non-exhaustive list of inventive subject matter according to the present disclosure, which may or may not be claimed.

[0005]

[0005] In one embodiment, a disclosed method for analyzing a toe layup design of a one-piece composite structure having a closed end geometry includes (1) receiving a design data file for the toe layup design of the one-piece composite structure having a closed end geometry from a design data file repository to at least one computing device via a communication network and a network interface; (2) processing the design data file on the at least one computing device to construct a three-dimensional model of the one-piece composite structure; (3) analyzing the three-dimensional model on the at least one computing device to evaluate modulus characteristics of the toe layup design; and (4) generating modulus result data on the at least one computing device based on the analysis of the three-dimensional model, the modulus result data reflecting the modulus characteristics of the toe layup design of the one-piece composite structure.

[0006]

[0006] In another embodiment, another disclosed method for analyzing a toe layup design of a one-piece composite structure having a closed end shape includes (1) selecting a design data file for a toe layup design of a one-piece composite structure having a closed end shape from a design data file repository; (2) constructing a three-dimensional model of the one-piece composite structure; (3) analyzing the three-dimensional model with at least one computing device to evaluate elastic modulus characteristics of the toe layup design; and (4) generating elastic modulus result data with the at least one computing device based on the analysis of the three-dimensional model, the elastic modulus result data reflecting the elastic modulus characteristics of the toe layup design of the one-piece composite structure.

[0007]

[0007] In yet another embodiment, yet another disclosed method for analyzing a toe layup design of a one-piece composite structure having a closed end geometry includes (1) selecting a design data file for a toe layup design of a one-piece composite structure having a closed end geometry from a design data file repository; (2) processing the design data file with at least one computing device to construct a three-dimensional model of the one-piece composite structure; (3) analyzing the three-dimensional model with at least one computing device to evaluate elastic modulus characteristics of the toe layup design; and (4) based on the analysis of the three-dimensional model, generating, with the at least one computing device, a three-dimensional model reflecting the elastic modulus characteristics of the toe layup design of the one-piece composite structure. and (5) performing at least one of: (i) storing the modulus result data on a data storage device accessible to the at least one computing device; (ii) printing the modulus result data on a printing device accessible to the at least one computing device; (iii) displaying the modulus result data on a display device accessible to the at least one computing device; and (iv) sending a message to an operator associated with the at least one computing device providing notification that the modulus result data is available and instructions for accessing the modulus result data.

[0008]

[0008] Other examples of the disclosed method for analyzing the toe layup design of a one-piece composite material having a closed end shape will become apparent from the following detailed description, the accompanying drawings, and the accompanying claims. [Brief explanation of the drawings]

[0009] [Figure 1]

[0009] FIG. 1 is a flow diagram of one embodiment of a method for analyzing the toe layup design of a one-piece composite structure having a closed end shape. [Figure 2]

[0010] FIG. 1 is a functional block diagram of an embodiment of a toe layup design. [Figure 3]

[0011] FIG. 1 is a perspective view of an embodiment of a one-piece composite structure. [Figure 4]

[0012] FIG. 1 is a functional block diagram of an embodiment of a system for analyzing the toe layup design of a one-piece composite structure having a closed end geometry. [Figure 5]

[0013] FIG. 1 is a functional block diagram of an example design data file for a one-piece composite structure. [Figure 6]

[0014] FIG. 2 is a flow diagram of one embodiment of processing a design data file in the method of FIG. 1. [Figure 7]

[0015] FIG. 1 is a side view of an example of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 8]

[0016] FIG. 2 is a flow diagram of an example of analysis of a three-dimensional model in the method of FIG. 1. [Figure 9]

[0017] FIG. 9 is a flow diagram of one example of an analysis of the elongated hollow section of FIG. 8. [Figure 10]

[0018] FIG. 9 is a flow diagram of one embodiment of the analysis of the closed end portion of FIG. 8. [Figure 11]

[0019] FIG. 9 is a flow diagram of one embodiment of the analysis of the transition portion of FIG. 8. [Figure 12]

[0020] FIG. 2 is a flow diagram of one embodiment of generating modulus result data in the method of FIG. 1. [Figure 13]

[0021] FIG. 13 is a flow diagram of one example of generating elastic modulus result data for the elongated hollow section of FIG. 12. [Figure 14]

[0022] FIG. 13 is a flow diagram of one example of generating elastic modulus result data for the closed end portion of FIG. 12. [Figure 15]

[0023] FIG. 13 is a flow diagram of one embodiment of generating modulus of elasticity result data for the transition section of FIG. 12. [Figure 16]

[0024] FIG. 2 is a flow diagram of another embodiment of a method for analyzing the toe layup design of a one-piece composite structure having a closed end geometry, in combination with FIG. 1 . [Figure 17]

[0025] FIG. 10 is a flow diagram of yet another embodiment of a method for analyzing a toe layup design of a one-piece composite structure having a closed end configuration. [Figure 18]

[0026] FIG. 18 is a flow diagram of one embodiment of constructing a three-dimensional model in the method of FIG. 17. [Figure 19]

[0027] FIG. 18 is a flow diagram of one embodiment of analysis of a three-dimensional model in the method of FIG. 17. [Figure 20]

[0028] FIG. 18 is a flow diagram of one embodiment of generating modulus result data in the method of FIG. 17. [Figure 21]

[0029] FIG. 18 is a flow diagram of yet another embodiment of a method for analyzing the toe layup design of a one-piece composite structure having a closed end geometry, in combination with FIG. 17; [Figure 22]

[0030] FIG. 10 is a flow diagram of yet another embodiment of a method for analyzing a toe layup design of a one-piece composite structure having a closed end configuration. [Figure 23]

[0031] FIG. 2 is a flow diagram of yet another embodiment of a method for analyzing the toe layup design of a one-piece composite structure having a closed end geometry, in combination with FIG. 1 . [Figure 24]

[0032] FIG. 18 is a flow diagram of another embodiment of a method for analyzing the toe layup design of a one-piece composite structure having a closed end geometry, in combination with FIG. 17; [Figure 25]

[0033] FIG. 23 is a flow diagram of yet another embodiment of a method for analyzing the toe layup design of a one-piece composite structure having a closed end geometry, in combination with FIG. 22; [Figure 26A]

[0034] FIG. 1 is a perspective view of an example of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 26B] FIG. 1 is an end view of an example of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 27]

[0035] FIG. 10 is a perspective view of another embodiment of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 28]

[0036] FIG. 10 is a perspective view of yet another example three-dimensional model showing multiple example lateral end slices, lateral transition region slices, and lateral elongate body slices of the three-dimensional model. [Figure 29]

[0037] 1 is an example of a heat map of a closed edge portion and transition portion of a three-dimensional model. [Figure 30A]

[0038] 1 is an example of a graph of a lateral edge slice of a three-dimensional model. [Figure 30B]

[0039] 30B is an example of a heat map of the lateral edge slice of FIG. 30A. [Figure 31A]

[0040] 1 is an example of a heat map of a transition portion of a three-dimensional model. [Figure 31B]

[0041] 1 is an example of a graph of a lateral transition region slice of a three-dimensional model. [Figure 31C]

[0042] 10 provides some example graphs of transition portions of a three-dimensional model. [Figure 32]

[0043] FIG. 10 is a perspective view of another embodiment of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 33]

[0044] FIG. 10 is a perspective view of yet another embodiment of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 34]

[0045] FIG. 10 is a perspective view of another embodiment of a three-dimensional model of a one-piece composite structure having a closed end geometry. [Figure 35]

[0046] FIG. 1 is a block diagram of an aircraft manufacturing and service methodology implementing one or more embodiment of the methodology for analyzing a toe layup design of a one-piece composite structure having closed end geometries disclosed herein. [Figure 36]

[0047] FIG. 1 is a schematic diagram of an aircraft incorporating components designed and constructed according to one or more embodiments of the method for analyzing toe layup designs of one-piece composite structures having closed end geometries disclosed herein. DETAILED DESCRIPTION OF THE INVENTION

[0010]

[0048] Various embodiments of the methods 100, 1600, 1700, 2100, 2200, 2300, 2400, and 2500 for analyzing a tow layup design 200 for a one-piece composite structure 300 with a closed end geometry 302 disclosed herein enable the use of an optimized approach for fiber distribution and alignment. The goal of this approach is to obtain a modulus within an acceptable range for quasi-isotropic laminate properties. Another goal is to reduce the modulus variation across the region. This approach also allows for lower variability and a higher desired modulus for the integration of composite components. Optimizing the modulus enables weight reduction and design optimization techniques, potentially saving costs and increasing the value (higher payload) of the product.

[0011]

[0049] Variations in the moduli Ex and Ey due to dome fiber contributions can be undesirable, for example, for pressure vessels. Given that these composite structures are very thin, the contribution of dome fiber variability is significant and therefore needs to be addressed. To mitigate this, contributions can be made from precisely positioned dome fibers so that there is a more desirable Ex modulus throughout and lower circumferential variability. To understand the modulus variability and amplitude, analytical tools are used to sample areas (e.g., collars) of the laminate (see, e.g., Figures 29, 30A-30B, and 31A-31C). These collars are analyzed for fiber angles relative to their respective locations and confirmed using modulus analysis heat maps (see, e.g., Figures 29, 30B, and 31A). Specific dome ply repeats and available intersection locations for the resulting moduli show how to transition from high variability with low Ex (standard layup, no optimization) to low variability and the desired Ex.

[0012]

[0050] 1-16 , 23 , 29 , 31A-31C , and 32-34 , by way of example, the present disclosure is directed to methods 100, 1600, 2300 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. FIG. 1 provides an example of a method 100 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. FIG. 2 illustrates an example of a toe layup design 200. FIG. 3 illustrates an example of a one-piece composite structure 300. FIG. 4 illustrates an example of a system for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. FIG. 5 illustrates an example of a design data file 402 for a one-piece composite structure 300. Figure 6 is an example of processing 104 a design data file 402 in the method 100 of Figure 1. Figure 7 shows an example of a three-dimensional model 414, 3200, 3300, 3400 of a one-piece composite structure 300 having a closed end shape 302. Figure 8 is an example of analyzing 106 a three-dimensional model 414, 3200, 3300, 3400 in the method 100 of Figure 1.

[0013]

[0051] FIG. 9 is an example of an analysis 802 of the elongated hollow section 702 of FIG. 8. FIG. 10 is an example of an analysis 804 of the closed end section 704 of FIG. 8. FIG. 11 is an example of an analysis 806 of the transition section 706 of FIG. 8. FIG. 12 is an example of generating 108 modulus of elasticity result data 420 in the method 100 of FIG. 1. FIG. 13 is an example of generating 1202 modulus of elasticity result data 420 of the elongated hollow section 702 of FIG. 12. FIG. 14 is an example of generating 1204 modulus of elasticity result data 420 of the closed end section 704 of FIG. 12. FIG. 15 is an example of generating 1206 modulus of elasticity result data 420 of the transition section 706 of FIG. 12. FIG. 16, in combination with FIG. 1, provides an example of a method 1600 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end configuration 302. FIG. 23, in combination with FIG. 1, provides one example of a method 2300 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302.

[0014]

[0052] Figure 29 shows an example heat map 2900 of the closed end portion 704 and transition portion 706 of a three-dimensional model 414, 3200, 3300, 3400. Figure 31A shows an example heat map 3102 of the transition portion 706 of a three-dimensional model 414, 3200, 3300, 3400. Figure 31B shows an example graph 3104 of the lateral transition region slice 716 of a three-dimensional model 414, 3200, 3300, 3400. Figure 31C shows several example graphs 3106 of the transition portion 706 of a three-dimensional model 414, 3200, 3300, 3400. Figure 32 shows another example three-dimensional model 3200 of a one-piece composite structure 300 having a closed end shape 302. Figure 33 shows yet another embodiment of a three-dimensional model 3300 of a one-piece composite structure 300 having a closed end geometry 302. Figure 34 shows yet another embodiment of a three-dimensional model 3400 of a one-piece composite structure 300 having a closed end geometry 302.

[0015]

[0053] 1-4 and 32-34 , in one or more embodiments, a method 100 (see FIG. 1 ) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes receiving 102 a design data file 402 for the toe layup design 200 of the one-piece composite structure 300 having a closed end geometry 302 from a design data file repository 404 via a communications network 406 and a network interface 408 to at least one computing device 410. At 104, the design data file 402 is processed by the at least one computing device 410 to construct a three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300. At 106, the three-dimensional models 414, 3200, 3300, 3400 are analyzed by at least one computing device 410 to evaluate the modulus of elasticity characteristics 418 of the tow layup design 200. At 108, modulus of elasticity results data 420 reflecting the modulus of elasticity characteristics 418 of the tow layup design 200 of the one-piece composite structure 300 is generated by the at least one computing device 410 based on the analysis 106 of the three-dimensional models 414, 3200, 3300, 3400.

[0016]

[0054] 1-4 , 23 , and 32-34 , in one or more embodiments, a method 2300 (see FIG. 23 ) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes the method 100 of FIG. 1 and proceeds from 108 to 2302, where a first measure of goodness is determined for modulus of elasticity results data 420 based on the design data file 402. At 2304, receiving 102, processing 104, analyzing 106, and generating 108 are repeated for a second toe layup design of the one-piece composite structure 300 and a second design data file to generate second modulus of elasticity results data based on the second design data file. At 2306, a second measure of goodness is determined for the second modulus of elasticity results data based on the second design data file. At 2308, the second measure of goodness is compared to the first measure of goodness. At 2310, an optimized tow layup design for the unitary composite structure 300 is selected from the tow layup design 200 and the second tow layup design based on comparing 2308. In another embodiment of the method 2300, the first measure of goodness and the second measure of goodness include a measure of isotropy across the three-dimensional model 414, 3200, 3300, 3400 or a portion thereof, a measure of laminate property variability across the three-dimensional model 414, 3200, 3300, 3400 or a portion thereof, a measure of elastic modulus of a selected property across the three-dimensional model 414, 3200, 3300, 3400 or a portion thereof, or any other suitable measure of goodness in any suitable combination.

[0017]

[0055] 1-15, 29, 31A-31C, and 32-34. In another embodiment of the method 100, the one-piece composite structure 300 includes an elongated hollow body 304, a closed end shape 302, and a transition region 306 between the elongated hollow body 304 and the closed end shape 302. In a further embodiment, the tow layup design 200 includes a strip layup design 202, a closed end layup design 206, and a transition layup design 210. The strip layup design 202 includes a first design data selection 204 in a design data file 402 that defines a plurality of sets of strip plies for the tow layup of the elongated hollow body 304. The closed end layup design 206 includes a second design data selection 208 in the design data file 402 that defines two or more sets of end plies for toe layup of the closed end shape 302. The transition layup design 210 includes a third design data selection 212 in the design data file 402 that defines the integration of the elongate plies and the end plies.

[0018]

[0056] In yet another embodiment of method 100, closed end shape 302 comprises a dome, a hemispherical dome, an elliptical dome, a semi-elliptical head, a torispherical head, a dished head, or any other suitable closed end shape in any suitable combination. In yet another embodiment of method 100, elongated hollow body 304 comprises a cylinder, a pipe, a tube, a cylindrical body, an ellipsoid, a contoured body, or any other suitable elongated hollow body in any suitable combination.

[0019]

[0057] In yet another embodiment of the method 100, the one-piece composite structure 300 includes an elongated hollow body 304, a closed end shape 302, and a transition region 306 between the elongated hollow body 304 and the closed end shape 302. In this embodiment, the elongated hollow body 304 extends longitudinally along an x-axis 308, and the circumference defines a y-direction 310. The design data file 402 includes a first design data section 204, a second design data section 208, and a third design data section 212. The first design data section 204 defines multiple sets of elongated body plies for toe layup of the elongated hollow body 304. The second design data section 208 defines two or more sets of end plies for toe layup of the closed end shape 302. The third design data section 212 defines the integration of the elongated body plies and the end plies at the transition region 306.

[0020]

[0058] In a further example, the first design data section 204 includes a set of geometric dimensions 502, a location of a strip reference axis 504, and a strip fiber angle 506. The set of geometric dimensions 502 is for a strip surface 312 of a mandrel 314 used to tow-lay up the strip plies. The strip surface 312 is associated with an elongated hollow body 304 of the one-piece composite structure 300. The location of the strip reference axis 504 is on the strip surface 312 to define a zero-degree fiber angle 316 for the strip plies. The strip fiber angle 506 of each set of strip plies relative to the strip reference axis 504. In yet a further example, the strip fiber angle 506 of each set of strip plies is based on the relative distribution of the strip plies at 0 degrees, 45 degrees, −45 degrees, or any other suitable angle or range of angles.

[0021]

[0059] In another further embodiment, the second design data selection 208 includes a set of geometric dimensions 508, a location of an end polar reference axis 510, and an end fiber angle 512. The set of geometric dimensions 508 is for an end face 318 of a mandrel 314 used for toe layup of the end plies. The end face 318 is associated with the closed end shape 302 of the one-piece composite structure 300. The location of the end polar reference axis 510 is on the end face 318 to define a zero-degree fiber angle 320 for the end plies. The end fiber angle 512 of each set of end plies is relative to the end polar reference axis 510. In yet a further embodiment, the end fiber angle 512 of each set of end plies is based on 180 degrees relative to the reference axis divided by the quantity of end plies in the corresponding set of end plies. In yet another embodiment, the number of end plies in the corresponding set of end plies includes 2 end plies, 3 end plies, 4 end plies, 5 end plies, 6 end plies, 8 end plies, 9 end plies, 10 end plies, or any other suitable number of end plies. In yet another embodiment, the end fiber angle 512 of the corresponding set of end plies includes a range of 90 degrees to 60 degrees, 60 degrees to 45 degrees, 45 degrees to 36 degrees, 36 degrees to 30 degrees, 30 degrees to 22.5 degrees, 22.5 degrees to 20 degrees, 20 degrees to 18 degrees, less than 18 degrees, or any other suitable angle range.

[0022]

[0060] In yet another embodiment, the third design data selection 212 includes a set of geometric dimensions 518, a strip fiber angle 506, an identification of a strip ply 520, physical dimensions 522 for the portion of the strip ply, a location of an end pole reference axis 510, an end fiber angle 512, an identification of the end ply 524, and physical dimensions 526 for the portion of the end ply. The set of geometric dimensions 518 is for a transition region surface 324 of a mandrel 314 used for the integrated tow layup of the strip plies and the end plies. The transition region surface 324 is associated with the transition region 306 of the integrated composite structure 300. The location of the strip reference axis 504 is on the strip surface 312 to define the zero-degree fiber angle 316 of the strip ply. A strip fiber angle 506 is for each set of strip plies relative to the strip reference axis 504. An identification of a strip ply 520 is for the strip ply 520 in each set of strip plies that extends into the transition region 306. A physical dimension 522 is for the portion of the strip ply in each set of strip plies that extends into the transition region 306. A location of the end polar reference axis 510 is on the end face 318 to define the zero degree fiber angle 320 of the end ply. An end fiber angle 512 is for each set of end plies relative to the end polar reference axis 510. An identification of a strip ply 524 is for the end ply in each set of end plies that extends into the transition region 306. A physical dimension 526 is for the portion of the end ply in each set of end plies that extends into the transition region 306.

[0023]

[0061] In yet a further embodiment, the strip plies extending into the transition region 306 and the end plies extending into the transition region 306 form a joint within the transition region 306. In yet another further embodiment, the joint within the transition region 306 comprises a scarf joint, a double scarf joint, an overlap joint, a butt joint, a series of joints, a series of joints at a common longitudinal position, a series of joints at staggered longitudinal positions, or any other suitable type of joint in any suitable combination. In yet another further embodiment, at least a portion of the strip plies extending into the transition region 306 overlaps at least a portion of the end plies extending into the transition region 306. In yet another further embodiment, at least a portion of the strip plies extending into the transition region 306 abuts at least a portion of the end plies extending into the transition region 306.

[0024]

[0062] In another embodiment of the method 100, at least one computing device 410 is configured to execute a three-dimensional modeling application program 412 in conjunction with processing 104 the design data file 402 to construct three-dimensional models 414, 3200, 3300, 3400.

[0025]

[0063] In yet another embodiment of the method 100, the one-piece composite structure 300 includes an elongated hollow body 304, a closed end feature 302, and a transition region 306 between the elongated hollow body 304 and the closed end feature 302. The elongated hollow body 304 extends longitudinally along an x-axis 308, and a circumference defines a y-direction 310. In this embodiment, processing 104 the design data file 402 includes generating 602 (see FIG. 6 ) an elongated hollow portion 702 of a three-dimensional model 414, 3200, 3300, 3400 of the elongated hollow body 304 based on the design data file 402 that defines a plurality of sets of elongated body plies for toe layup of the elongated hollow body 304. At 604, a closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 is generated for the closed end shape 302 based on the design data file 402 that defines two or more sets of end plies for toe layup of the closed end shape 302. At 606, a transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 is generated for the transition region 306 based on the design data file 402 that defines the integration of the strip plies and the end plies within the transition region 306.

[0026]

[0064] In a further example, the elongated hollow portion 702 of the three-dimensional model 414, 3200, 3300, 3400 includes each strip ply of each of the multiple sets of strip plies and fiber orientation information for the strips in each strip ply. In another further example, the closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 includes each end ply of each of two or more sets of end plies and fiber orientation information for the ends of each end ply. In yet another example, the transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 includes each strip ply of each of the multiple sets of strip plies that extend into the transition region 306 and fiber orientation information for the strips in each of the strip plies. The transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 includes each end ply of each of two or more sets of end plies that extend into the transition region 306, and fiber direction information for the end of each of the end plies.

[0027]

[0065] In yet another embodiment of the method 100, at least one computing device 410 is configured to execute an elastic modulus analysis application program 416 in conjunction with the analysis 106 of the three-dimensional model 414, 3200, 3300, 3400 to determine elastic modulus properties 418.

[0028]

[0066] In yet another embodiment of the method 100, the three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300 includes an elongated hollow strip portion 702, a closed end portion 704, and a transition portion 706 between the elongated hollow strip portion 702 and the closed end portion 704. The elongated hollow strip 702 extends longitudinally along the x-axis 308, and the circumference defines the y-direction 310. In this embodiment, analyzing 106 the three-dimensional model 414, 3200, 3300, 3400 includes analyzing 802 (see FIG. 8 ) the elongated hollow strip portion 702 of the three-dimensional model 414, 3200, 3300, 3400 based on a three-dimensional representation of each elongated body ply of each of a plurality of sets of elongated body plies for a toe layup of the elongated hollow strip 304. Each elongated body ply includes fiber orientation information for the elongated body. At 804, the closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 is analyzed based on a three-dimensional representation of each end ply for each of two or more sets of end plies for the toe layup of the closed end shape 302. Each end ply includes fiber direction information for the end. At 806, the transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 is analyzed based on a three-dimensional representation of each strip ply extending into the transition region 306 and each end ply extending into the transition region 306.

[0029]

[0067] In a further embodiment, analyzing 802 an elongated hollow portion 702 of a three-dimensional model 414, 3200, 3300, 3400 includes dividing 902 the elongated hollow portion 702 into a plurality of lateral strip slices 708 (see FIG. 9 ). At 904, each lateral strip slice 708 is divided into a plurality of core samples 710 extending from the strip surface 312 through the thickness of the elongated hollow portion 702. At 906, each core sample 710 of each lateral strip slice 708 is analyzed to determine the collective strip fiber orientation of the corresponding core sample 710 and to determine the modulus of elasticity property 418 of the core sample 710 relative to adjacent core samples 710. In another further embodiment, analyzing 804 a closed end portion 704 of a three-dimensional model 414, 3200, 3300, 3400 includes dividing 1002 (see FIG. 10 ) the closed end portion 704 into a plurality of lateral end slices 712. At 1004, each lateral end slice 712 is divided into a plurality of core samples 714 extending from the end face 318 through the thickness of the closed end portion 704. At 1006, each core sample 714 of each lateral end slice 712 is analyzed to determine the aggregate end fiber orientation of the corresponding core sample 714 and to determine the modulus of elasticity property 418 of the core sample 714 relative to adjacent core samples 714. In yet another embodiment, analyzing 806 the transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 includes dividing 1102 the transition portion 706 into a plurality of lateral transition region slices 716 (see FIG. 11 ). At 1104, each lateral transition region slice 716 is divided into a plurality of core samples 718 extending from the transition region surface 324 through the thickness of the transition portion 706. At 1106, each core sample 718 in each lateral transition region slice 716 is analyzed to determine the aggregate transition region fiber orientation of the corresponding core sample 718 and to determine the modulus of elasticity property 418 of the core sample 718 relative to adjacent core samples 718.

[0030]

[0068] In yet another embodiment of the method 100, the three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300 includes an elongated hollow portion 702, a closed end portion 704, and a transition portion 706 between the elongated hollow portion 702 and the closed end portion 704. The elongated hollow portion 702 extends longitudinally along the x-axis 308, and a circumference defines the y-direction 310. In this embodiment, generating 108 the modulus of elasticity result data 420 includes generating 1202 (see FIG. 12 ) the modulus of elasticity result data 420 for the elongated hollow portion 702 of the three-dimensional model 414, 3200, 3300, 3400 based on the modulus of elasticity property 418 from the analysis of the toe layup design 200 of the elongated hollow portion 702. At 1204, modulus result data 420 for the closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 is generated based on the modulus characteristic 418 from the analysis of the toe layup design 200 of the closed end portion 704. At 1206, modulus result data 420 for the transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 is generated based on the modulus characteristic 418 from the analysis of the toe layup design 200 of the transition portion 706.

[0031]

[0069] In a further embodiment, generating 1202 the modulus of elasticity result data 420 for the elongated hollow portion 702 includes arranging 1302 (see FIG. 13 ) the modulus of elasticity result data 420 for the elongated hollow portion 702 into a plurality of lateral strip slices 708 and a plurality of core samples 710 following the circumference of the corresponding lateral strip slices 708, the core samples 710 extending from the strip surface 312 through the thickness of the elongated hollow portion 702. The modulus of elasticity result data 420 for each core sample 710 includes the aggregate strip fiber direction of the corresponding core sample 710 and the modulus of elasticity characteristic 418 of the core sample 710 relative to adjacent core samples 710. In yet a further embodiment, generating 1202 the modulus of elasticity result data 420 for the hollow elongate portion 702 also includes generating 1304 at least one of a tabular report, a graph, and a heat map for at least one lateral strip slice 708 of the hollow elongate portion 702. At 1306, at least one of a tabular report, a graph, and a heat map for the hollow elongate portion 702 is generated.

[0032]

[0070] In yet another embodiment, generating 1204 modulus result data 420 for closed end portion 704 includes generating 1204 modulus result data 420 for closed end portion 704 The method includes distributing 1402 (see FIG. 14 ) modulus result data 420 to a plurality of lateral end slices 712 and a plurality of core samples 710 that follow the circumference of the corresponding lateral end slices 712. The core samples 710 extend from the end face 318 through the thickness of the closed end portion 704. The modulus result data 420 for each core sample 710 includes the fiber direction of the collective end of the corresponding core sample 710 and the modulus of elasticity properties 418 of the core sample 710 relative to adjacent core samples 710. In yet a further embodiment, generating 1204 modulus result data 420 for the closed end portion 704 also includes generating 1404 at least one of a tabular report, a graph 3002, and a heat map 3004 for at least one lateral end slice 712 of the closed end portion 704. At 1406, at least one of a tabular report, a graph, and a heat map 2900, 3102 for the closed end portion 704 is generated.

[0033]

[0071] In yet another embodiment, generating 1206 the modulus result data 420 for the transition portion 706 includes arranging 1502 (see FIG. 15 ) the modulus result data 420 for the transition portion 706 into a plurality of lateral transition zone slices 716 and a plurality of core samples following the circumference of the corresponding lateral transition zone slices 716. The core samples extend from the transition zone surface 324 through the thickness of the transition portion 706. The modulus result data 420 for each core sample includes the aggregate transition zone fiber direction of the corresponding core sample and the modulus of elasticity characteristics 418 of the core sample relative to adjacent core samples. In yet a further embodiment, generating 1206 the modulus result data 420 for the transition portion 706 also includes generating 1504 at least one of a tabular report, a graph 3104, and a heat map 2900, 3102 for at least one lateral transition zone slice 716 of the transition portion 706. At 1506, at least one of a tabular report, a graph 3106, and a heat map 2900, 3102 for the transition portion 706 is generated.

[0034]

[0072] 1 , 4 , and 16 , in one or more embodiments, a method 1600 (see FIG. 16 ) for analyzing a toe layup design 200 for a one-piece composite structure 300 having a closed end geometry 302 includes the method of FIG. 1 and proceeds from 108 to 1602, where at least one of four options is performed. The first option is storing 1602 the modulus of elasticity results data 420 in a data storage device 422 accessible to the at least one computing device 410. The second option is printing 1604 the modulus of elasticity results data 420 with a printing device 424 accessible to the at least one computing device 410. The third option is displaying 1606 the modulus of elasticity results data 420 on a display device 426 accessible to the at least one computing device 410. A fourth option is to send 1608 a message to an operator associated with the at least one computing device 410 providing notification that the modulus results data 420 is available and instructions for accessing the modulus results data 420. In another embodiment, the at least one computing device 410 may include at least one processor 428, associated memory 430, and input device 432.

[0035]

[0073]

[0033] Generally, with reference to Figures 2-4, 7, 17-21, 24, and 32-34, the present disclosure is directed to methods 1700, 2100, 2400 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. Figure 2 illustrates an example of a toe layup design 200. Figure 3 illustrates an example of a one-piece composite structure 300. Figure 4 illustrates an example of a system for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. Figure 7 illustrates an example of a three-dimensional model 414, 3200, 3300, 3400 of a one-piece composite structure 300 having a closed end geometry 302. Figure 17 provides an example of a method 1700 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. Figure 18 provides one example of constructing 1704 the three-dimensional models 414, 3200, 3300, 3400 in the method 1700 of Figure 17. Figure 19 provides one example of analyzing 1706 the three-dimensional models 414, 3200, 3300, 3400 in the method 1700 of Figure 17. Figure 20 provides one example of generating 1708 the modulus of elasticity result data 420 in the method 1700 of Figure 17.

[0036]

[0074] Figure 21 , in combination with Figure 17 , provides an example of a method 2100 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end shape 302. Figure 24 , in combination with Figure 17 , provides an example of a method 2400 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end shape 302. Figure 32 shows another example of a three-dimensional model 3200 of a one-piece composite structure 300 having a closed end shape 302. Figure 33 shows yet another example of a three-dimensional model 3300 of a one-piece composite structure 300 having a closed end shape 302. Figure 34 shows yet another example of a three-dimensional model 3400 of a one-piece composite structure 300 having a closed end shape 302.

[0037]

[0075] 2-4, 17, and 32-34, in one or more embodiments, a method 1700 (see FIG. 17) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes selecting 1702 a design data file 402 for the toe layup design 200 of the one-piece composite structure 300 having a closed end geometry 302 from a design data file repository 404. At 1704, a three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300 is constructed. At 1706, the three-dimensional model 414, 3200, 3300, 3400 is analyzed with at least one computing device 410 to evaluate a modulus of elasticity characteristic 418 of the toe layup design 200. At 1708, modulus result data 420 reflecting modulus characteristics 418 of the toe layup design 200 of the integrated composite structure 300 is generated at the at least one computing device 410 based on the analysis 1706 of the three-dimensional models 414, 3200, 3300, 3400.

[0038]

[0076] 2-4, 17, and 24, in one or more embodiments, a method 2400 (see FIG. 24) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes method 1700 of FIG. 17 and proceeds from 1708 to 2402, where a first measure of goodness is determined for modulus of elasticity results data 420 based on design data file 402. At 2404, selecting 1702, constructing 1704, analyzing 1706, and generating 1708 are repeated for a second toe layup design of the one-piece composite structure 300 and a second design data file to generate second modulus of elasticity results data based on the second design data file. At 2406, a second measure of goodness is determined for the second modulus of elasticity results data based on the second design data file. At 2408, the second measure of goodness is compared to the first measure of goodness. At 2410, an optimized tow layup design for the one-piece composite structure 300 is determined from the tow layup design 200 and the second tow layup design based on comparing 2408.

[0039]

[0077] 2-4, 7, 17-21, and 32-34. In another embodiment of method 1700, a one-piece composite structure 300 includes an elongated hollow body 304, a closed end shape 302, and a transition region 306 between the elongated hollow body 304 and the closed end shape 302. The elongated hollow body 304 extends longitudinally along an x-axis 308, and a circumference defines a y-direction 310. In this embodiment, the design data file 402 includes a first design data section 204, a second design data section 208, and a third design data section 212. The first design data section 204 defines multiple sets of elongated body plies for toe layup of the elongated hollow body 304. The second design data section 208 defines two or more sets of end plies for toe layup of the closed end shape 302. The third design data section 212 defines the integration of the elongate body plies and the end plies in the transition region 306 .

[0040]

[0078] In yet another embodiment of the method 1700, constructing 1704 the three-dimensional model 414, 3200, 3300, 3400 includes executing 1802 (see FIG. 18 ) a three-dimensional modeling application program 412 on the design data file 402 using at least one computing device 410 in conjunction with constructing 1704 the three-dimensional model 414, 3200, 3300, 3400. In a further embodiment, the one-piece composite structure 300 includes an elongated hollow body 304, a closed end feature 302, and a transition region 306 between the elongated hollow body 304 and the closed end feature 302. The elongated hollow body 304 extends longitudinally along an x-axis 308, and a circumference defines a y-direction 310. In this example, constructing 1704 the three-dimensional model 414, 3200, 3300, 3400 also includes generating 1804 the elongated hollow portion 702 of the three-dimensional model 414, 3200, 3300, 3400 of the elongated hollow body 304 based on a design data file 402 that defines a plurality of sets of elongated body plies for toe layup of the elongated hollow body 304. At 1806, a closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 is generated for the closed end shape 302 based on the design data file 402 that defines two or more sets of end plies for a toe layup of the closed end shape 302. At 1808, a transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 is generated for the transition region 306 based on the design data file 402 that defines the integration of the elongate plies and the end plies in the transition region 306. In yet another embodiment of the method 1700, the at least one computing device 410 is configured to execute a modulus analysis application program 416 in conjunction with the analysis 1706 of the three-dimensional model 414, 3200, 3300, 3400 to determine a modulus of elasticity characteristic 418.

[0041]

[0079] In yet another embodiment of the method 1700, the three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300 includes an elongated hollow portion 702, a closed end portion 704, and a transition portion 706 between the elongated hollow portion 702 and the closed end portion 704. The elongated hollow portion 702 extends longitudinally along the x-axis 308, and the circumference defines the y-direction 310. In this embodiment, analyzing 1706 the three-dimensional model 414, 3200, 3300, 3400 includes analyzing 1902 (see FIG. 19 ) the elongated hollow portion 702 of the three-dimensional model 414, 3200, 3300, 3400 based on a three-dimensional representation of each elongated body ply of each of a plurality of sets of elongated body plies for a toe layup of the elongated hollow portion 304. Each strip ply includes fiber orientation information for the strip. At 1904, the closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 is analyzed based on a three-dimensional representation of each end ply for each of two or more sets of end plies for a toe layup of the closed end shape 302. Each end ply includes fiber orientation information for the end. At 1906, the transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 is analyzed based on a three-dimensional representation of each strip ply extending into the transition region 306 and each end ply extending into the transition region 306.

[0042]

[0080] In another example embodiment of the method 1700, the three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300 includes an elongated hollow portion 702, a closed end portion 704, and a transition portion 706 between the elongated hollow portion 702 and the closed end portion 704. The elongated hollow portion 702 extends longitudinally along the x-axis 308, and a circumference defines the y-direction 310. In this example, generating 1708 the modulus of elasticity result data 420 includes generating 2002 (see FIG. 20 ) the modulus of elasticity result data 420 for the elongated hollow portion 702 of the three-dimensional model 414, 3200, 3300, 3400 based on the modulus of elasticity property 418 from the analysis of the toe layup design 200 of the elongated hollow portion 702. At 2004, modulus of elasticity result data 420 for the closed end portion 704 of the three-dimensional model 414, 3200, 3300, 3400 is generated based on the modulus of elasticity characteristic 418 from the analysis of the toe layup design 200 of the closed end portion 704. At 2006, modulus of elasticity result data 420 for the transition portion 706 of the three-dimensional model 414, 3200, 3300, 3400 is generated based on the modulus of elasticity characteristic 418 from the analysis of the toe layup design 200 of the transition portion 706.

[0043]

[0081] 4, 17, and 21, in one or more embodiments, a method 2100 (see FIG. 21) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes the method of FIG. 17 and proceeds from 1708 to 2102, in which at least one of four options is performed. The first option is storing 2102 the modulus of elasticity results data 420 in a data storage device 422 accessible to the at least one computing device 410. The second option is printing 2104 the modulus of elasticity results data 420 with a printing device 424 accessible to the at least one computing device 410. The third option is displaying 2106 the modulus of elasticity results data 420 on a display device 426 accessible to the at least one computing device 410. A fourth option is to send 2108 a message to an operator associated with at least one computing device 410 providing notification that the modulus result data 420 is available and instructions for accessing the modulus result data 420.

[0044]

[0082] 2-4, 22, 25, and 32-34, the present disclosure is directed to methods 2200, 2500 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. FIG. 2 illustrates an example of a toe layup design 200. FIG. 3 illustrates an example of a one-piece composite structure 300. FIG. 4 illustrates an example of a system for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. FIG. 22 provides an example of a method 2200 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. FIG. 25, in combination with FIG. 22, provides an example of a method 2500 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302. Figure 32 shows another embodiment of a three-dimensional model 3200 of a one-piece composite structure 300 having a closed end geometry 302. Figure 33 shows yet another embodiment of a three-dimensional model 3300 of a one-piece composite structure 300 having a closed end geometry 302. Figure 34 shows yet another embodiment of a three-dimensional model 3400 of a one-piece composite structure 300 having a closed end geometry 302.

[0045]

[0083] 2-4, 22, and 32-34, in one or more embodiments, a method 2200 (see FIG. 22) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes selecting 2202 a design data file 402 for the toe layup design 200 of the one-piece composite structure 300 having a closed end geometry 302 from a design data file repository 404. In 2204, the design data file 402 is processed by at least one computing device 410 to construct a three-dimensional model 414, 3200, 3300, 3400 of the one-piece composite structure 300. In 2206, the three-dimensional model 414, 3200, 3300, 3400 is analyzed by the at least one computing device 410 to evaluate a modulus of elasticity characteristic 418 of the toe layup design 200. At 2208, modulus result data 420 reflecting modulus properties 418 of the tow layup design 200 of the one-piece composite structure 300 is generated at the at least one computing device 410 based on the analysis 2206 of the three-dimensional model 414, 3200, 3300, 3400. At least one of four options is performed at 2210. A first option is to store the modulus result data 420 in a data storage device 422 accessible to the at least one computing device 410. A second option is to print the modulus result data 420 on a printing device 424 accessible to the at least one computing device 410. A third option is to display the modulus result data 420 on a display device 426 accessible to the at least one computing device 410. A fourth option is to send a message to an operator associated with at least one computing device 410 providing notification that the modulus result data 420 is available and instructions for accessing the modulus result data 420.

[0046]

[0084] 3 , 4 , 22 , and 25 , in one or more embodiments, a method 2500 (see FIG. 25 ) for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 includes method 2200 of FIG. 22 and proceeds from 2210 to 2502, where a first measure of goodness is determined for modulus of elasticity result data 420 based on design data file 402. At 2504, selecting 2202, processing 2204, analyzing 2206, and generating 2208 are repeated for a second toe layup design of the one-piece composite structure 300 and a second design data file to generate second modulus of elasticity result data based on the second design data file. At 2506, a second measure of goodness is determined for the second modulus of elasticity result data based on the second design data file. At 2508, the second measure of goodness is compared to the first measure of goodness. At 2510, an optimized tow layup design for the one-piece composite structure 300 is selected from the tow layup design 200 and the second tow layup design based on comparing 2508.

[0047]

[0085] 2-4, 22, and 32-34, in another embodiment of the method 2200, at least one computing device 410 is configured to execute a three-dimensional modeling application program 412 in conjunction with processing 2204 the design data file 402 to construct three-dimensional models 414, 3200, 3300, 3400. In yet another embodiment of the method 2200, at least one computing device 410 is configured to execute a modulus of elasticity analysis application program 416 in conjunction with analyzing 2206 the three-dimensional models 414, 3200, 3300, 3400 to determine modulus of elasticity properties 418.

[0048]

[0086] In yet another embodiment of method 2200, the first set of end plies in design data file 402 includes a first end ply having a first physical characteristic, a second end ply having a second physical characteristic different from the first physical characteristic, a third end ply having a third physical characteristic different from the second physical characteristic, and a fourth end ply having a fourth physical characteristic different from the third physical characteristic. In a further embodiment, the fiber angle from the first end ply to the fourth end ply averages 45 degrees. In another further embodiment, the first set of end plies also includes a fifth end ply having a fifth physical characteristic different from the fourth physical characteristic. In yet a further embodiment, the fiber angle from the first end ply to the fifth end ply averages 36 degrees. In yet another yet further embodiment, the first set of end plies also includes a sixth end ply having a sixth physical characteristic different from the fifth physical characteristic. In yet a still further embodiment, the fiber angle from the first end ply to the sixth end ply averages 30 degrees. In another yet further embodiment, the first set of end plies also includes a seventh end ply and an eighth end ply. The seventh end ply has a seventh physical property different from the sixth physical property. The eighth end ply has an eighth physical property different from the seventh physical property. In yet a still further embodiment, the fiber angle from the first end ply to the eighth end ply has an average of 22.5 degrees.

[0049]

[0087] Embodiments of the methods 100, 1600, 1700, 2100, 2200, 2300, 2400, 2500 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 may be related to or used in the context of aircraft manufacturing. While an aerospace example is shown, the embodiments and principles disclosed herein may be applied to other products, such as in the automotive, aerospace, construction, and other design and manufacturing industries. Thus, in addition to aircraft, the embodiments and principles disclosed herein may be applied to the use of composite products in the manufacture of various types of vehicles and the construction of various types of buildings.

[0050]

[0088] The foregoing detailed description refers to the accompanying drawings, which illustrate specific embodiments described by the present disclosure. Other embodiments having different structures and steps do not depart from the scope of the present disclosure. Like reference numerals may represent the same feature, element, or component in various drawings. Throughout this disclosure, any of a plurality of items may be referred to individually as that item, and a plurality of items may be referred to collectively as items (plural) and may be represented by like reference numerals. Furthermore, as used herein, a feature, element, component, or step preceded by the term "a" or "an" should be understood not to exclude a plurality of features, elements, components, or steps, unless expressly stated to exclude it.

[0051]

[0089] Illustrative, non-exhaustive examples of the inventive subject matter according to the present disclosure may be, but are not necessarily, claimed. Reference herein to an "example" means that one or more features, structures, elements, components, properties, and / or operational steps described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Thus, the phrases "one example," "another example," "one or more examples," and similar phrases used throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, subject matter characterizing any one of the examples may, but does not necessarily, include subject matter characterizing any other example. Furthermore, subject matter characterizing any one of the examples may, but does not necessarily, be combined with subject matter characterizing any other example.

[0052]

[0090] As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured to" perform a particular function is, in fact, capable of performing that particular function without any modification, rather than merely having the potential to perform that particular function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, "configured to" refers to an existing characteristic of a system, apparatus, device, structure, article, element, component, or hardware that enables the system, apparatus, device, structure, article, element, component, or hardware to perform a particular function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may additionally or alternatively be described as "adapted" and / or "operating" to perform that function.

[0053]

[0091] Unless otherwise indicated, terms such as "first," "second," "third," etc. are used herein merely as designators and are not intended to impose any sequential, positional, or hierarchical requirements on the items to which they refer. Furthermore, a reference to, e.g., a "second" item does not require or preclude the presence of, e.g., a "first" or lower-numbered item and / or, e.g., a "third" or higher-numbered item.

[0054]

[0092] As used herein, the phrase "at least one of" used in conjunction with listed items means that various combinations of one or more of the listed items may be used, and that only one of each listed item may be required. For example, "at least one of item A, item B, and item C" may include, but is not limited to, "item A," or "item A and item B." This example may also include item A, item B, and item C, or item B and item C. In other examples, "at least one of" may be, for example, but is not limited to, "two item A, one item B, and ten item C," "four item B, and seven item C," and other suitable combinations. As used herein, the phrase "and / or" and the indicia " / " include any and all combinations of one or more of the associated listed items.

[0055]

[0093] As used herein, "coupled," "coupling," and similar terms refer to two or more elements that are coupled, connected, fastened, connected, in communication, or otherwise associated with one another (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various examples, these elements may be directly associated or indirectly associated. For example, element A may be directly associated with element B. As another example, element A may be associated with element B, e.g., through another element C. It should be understood that not all relationships between the various disclosed elements are necessarily depicted. Thus, other couplings may exist than those shown in the figures.

[0056]

[0094] As used herein, the term "approximately" refers to or describes a condition that is close to, but not exactly, a specified condition that still performs a desired function or achieves a desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or precision, such as within 10% of the specified condition. However, the term "approximately" does not exclude a condition that is exactly the specified condition. As used herein, the term "substantially" refers to a condition that is essentially a specified condition that performs a desired function or achieves a desired result.

[0057]

[0095] In the above-referenced FIGS. 1, 6, and 8-25, multiple blocks may represent operations, steps, and / or portions thereof, and the lines connecting various blocks do not imply any particular order or dependency of the operations or portions thereof. It should be understood that not all dependencies between the various disclosed processes are necessarily depicted. FIGS. 1, 6, and 8-25, as well as the accompanying disclosure describing the operations disclosed herein, should not be construed as necessarily dictating the order in which operations should be performed. Rather, although one exemplary order is shown, it should be understood that the sequence of operations may be altered as needed. Accordingly, modifications, additions, and / or omissions may be made to the illustrated operations, and certain operations may be performed in a different order or simultaneously. Additionally, those skilled in the art will recognize that not all of the operations described need be performed.

[0058]

[0096] 2-5, 7, 26A-26B, and 27-34 referenced above may depict functional elements, features, or components thereof and do not necessarily imply any particular structure. Accordingly, modifications, additions, and / or omissions may be made to the illustrated configurations. Furthermore, those skilled in the art will understand that not all elements, features, and / or components described and shown in the above-referenced FIGS. 2-5, 7, 26A-26B, and 27-34 need be included in every embodiment, and not all elements, features, and / or components described herein will necessarily be shown in each illustrative embodiment. Thus, some of the elements, features, and / or components described and shown in FIGS. 2-5, 7, 26A-26B, and 27-34 may be combined in various ways without necessarily including other features described and shown in FIGS. 2-5, 7, 26A-26B, and 27-34, other figures, and / or the accompanying disclosure, although such combinations are not expressly set forth herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. Unless otherwise specified, the example schematics depicted in the above-referenced FIGS. 2-5, 7, 26A-26B, and 27-34 do not imply architectural limitations with respect to the illustrative embodiments. Rather, it should be understood that while one example configuration is shown, it may be modified as appropriate. Accordingly, modifications, additions, and / or omissions may be made to the illustrated configuration. Additionally, elements, features, and / or components that serve similar, or at least substantially similar, purposes are similarly numbered in each of Figures 2-5, 7, 26A-26B, and 27-34, and such elements, features, and / or components may not be described in detail herein when referring to each of Figures 2-5, 7, 26A-26B, and 27-34. Similarly, not all elements, features, and / or components may be numbered in each of Figures 2-5, 7, 26A-26B, and 27-34, but their associated reference numbers may be used consistently herein.

[0059]

[0097] Furthermore, throughout this specification, references to features, advantages, or similar language as used herein do not imply that all of the features and advantages that may be realized in the examples disclosed herein should or are in any single example. Rather, language referring to features and advantages is understood to mean that the particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, descriptions of features, advantages, and similar language as used throughout this disclosure may, but do not necessarily, refer to the same single example.

[0060]

[0098] Examples of the subject matter disclosed herein may be described in the context of an aircraft manufacturing and service method 3500 shown in FIG. 35 and an aircraft 3600 shown in FIG. 36 . In one or more embodiments, the disclosed methods 100, 1600, 1700, 2100, 2200, 2300, 2400, 2500 for analyzing a tow layup design 200 of a one-piece composite structure 300 having a closed end shape 302 may be used in aircraft manufacturing. During pre-production, the service method 3500 may include specification and design of the aircraft 3600 (block 3502) and material procurement (block 3504). During production, component and subassembly manufacturing (block 3506) and system integration (block 3508) of the aircraft 3600 may occur. The aircraft 3600 may then undergo certification and delivery (block 3510) and be placed into service (block 3512). While in service, the aircraft 3600 may be scheduled for routine maintenance and upkeep (block 3514), which may include modifying, reconfiguring, refurbishing, etc., one or more systems of the aircraft 3600.

[0061]

[0099] Each of the processes of method 3500 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military organization, a service organization, etc.

[0062]

[0100] As shown in FIG. 36 , an aircraft 3600 produced by maintenance method 3500 may include an airframe 3602 having a number of high-level systems 3604 and an interior 3606. Examples of high-level systems 3604 include one or more of a propulsion system 3608, an electrical system 3610, a hydraulic system 3612, and an environmental system 3614. Any number of other systems may be included. While an aerospace example is provided, the principles disclosed herein may also be applied to other industries, such as the automotive industry. As such, in addition to the aircraft 3600, the principles disclosed herein may also be applied to other vehicles, such as land vehicles, marine vehicles, space vehicles, etc.

[0063]

[0101] The disclosed methods 100, 1600, 1700, 2100, 2200, 2300, 2400, 2500 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end geometry 302 may be employed during any one or more of a plurality of stages of a manufacturing and service method 3500. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 3506) may be fabricated or manufactured in a manner similar to components or subassemblies manufactured during the operation of the aircraft 3600 (block 3512). Additionally, one or more embodiments of the system(s), method(s), or combinations thereof may be utilized during the manufacturing stage (blocks 3506 and 3508), for example, by substantially streamlining or reducing the cost of assembling the aircraft 3600. Similarly, one or more embodiments implementing the system or method, or combinations thereof, may be utilized, by way of example and not limitation, during operation of the aircraft 3600 (block 3512) and / or during maintenance and service (block 3514).

[0064]

[0102] The described features, advantages, and characteristics of one embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will recognize that the embodiments described herein may be practiced without one or more of the specific features or advantages of a particular embodiment. In other cases, additional features and advantages may be recognized in certain embodiments that are not present in all embodiments. Furthermore, while various embodiments of the method 100, 1600, 1700, 2100, 2200, 2300, 2400, 2500 for analyzing a toe layup design 200 of a one-piece composite structure 300 having a closed end shape 302 have been shown and described, numerous variations will occur to those skilled in the art upon reading this specification. The present application includes such variations and is limited only by the scope of the claims.

Claims

1. 1. A method (100) for analyzing a toe layup design (200) of a one-piece composite structure (300) having a closed end geometry (302), comprising: receiving (102) a design data file (402) for the toe layup design (200) of the one-piece composite structure (300) having the closed end shape (302) from a design data file repository (404) via a communications network (406) and a network interface (408) to at least one computing device (410); processing (104) the design data file (402) on the at least one computing device (410) to construct a three-dimensional model (414, 3200, 300, 3400) of the integrated composite structure (300); analyzing (106) the three-dimensional model (414, 3200, 3300, 3400) with the at least one computing device (410) to evaluate a modulus of elasticity characteristic (418) of the toe layup design (200); and generating (108), at the at least one computing device (410), based on the analysis (106) of the three-dimensional model (414, 3200, 3300, 3400), modulus result data (420) reflecting the modulus characteristics (418) of the toe layup design (200) of the integrated composite structure (300).

2. determining (2302) a first measure of goodness for the modulus of elasticity result data (420) based on the design data file (402); repeating (2304) the receiving (102), the processing (104), the analyzing (106), and the generating (108) for a second tow layup design of the one-piece composite structure (300) and the second design data file to generate second modulus of elasticity result data based on the second design data file; determining 2306 a second measure of goodness for the second modulus of elasticity result data based on the second design data file; comparing the second measure of goodness to the first measure of goodness (2308); and 10. The method of claim 1, further comprising: selecting (2310) an optimized toe layup design for the one-piece composite structure (300) from the toe layup design (200) and the second toe layup design based on the comparing (2308).

3. 3. The method of claim 2, wherein the first measure of goodness and the second measure of goodness include at least one of a measure of isotropy across the three-dimensional model (414, 3200, 3300, 3400) or portion thereof, a measure of laminate property variability across the three-dimensional model (414, 3200, 3300, 3400) or portion thereof, and a measure of elastic modulus of a selected property across the three-dimensional model (414, 3200, 3300, 3400) or portion thereof.

4. The one-piece composite structure (300) comprises: an elongated hollow body (304); the closed end shape (302), and The method of claim 1 , including a transition region (306) between the elongated hollow body (304) and the closed end configuration (302).

5. The toe layup design (200) a strip layup design (202) including a first design data section (204) in the design data file (402) defining a plurality of sets of strip plies for toe layup of the elongated hollow body (304); a closed end layup design (206) including a second design data section (208) in the design data file (402) that defines two or more sets of end plies for toe layup of the closed end shape (302); and 5. The method of claim 4, further comprising a transitional layup design including a third design data section in the design data file that defines the integration of the strip ply and the end ply.

6. The method of claim 1 , wherein the closed end shape (302) comprises at least one of a dome, a hemispherical dome, an elliptical dome, a semi-elliptical head, a tri-spherical head, and a dished head.

7. The method of claim 1 , wherein the elongated hollow body (304) comprises at least one of a cylinder, a pipe, a tube, a cylindrical body, an ellipsoid, and a curvilinear body.

8. The one-piece composite structure (300) includes an elongated hollow body (304), the closed end feature (302), and a transition region (306) between the elongated hollow body (304) and the closed end feature (302), the elongated hollow body (304) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the design data file (402) includes: a first design data section (204) defining a plurality of sets of elongated body plies for toe layup of said elongated hollow body (304); a second design data section (208) defining two or more sets of end plies for toe layup of the closed end shape (302); and The method of claim 1, further comprising a third design data section (212) defining integration of the strip ply and the end ply at the transition region (306).

9. The first design data section (204) comprises: a set of geometric dimensions (502) for a strip surface (312) of a mandrel (314) used in tow-laying up the strip plies, the strip surface (312) being associated with the elongated hollow body (304) of the one-piece composite structure (300); the location of a strip pole reference axis (504) on the strip surface (312) to define a zero degree fiber angle (316) of the strip ply; and The method of claim 8, including a strip fiber angle (506) of each set of strip plies relative to a reference axis (504) of the strip pole.

10. The method of claim 9, wherein the strip fiber angle (506) for each set of strip plies is based on the relative distribution of the strip plies at 0 degrees, 45 degrees, and -45 degrees.

11. The second design data section (208) comprises: a set of geometric dimensions (508) for an end face (318) of a mandrel (314) used in toe-laying up the end ply, the end face (318) being associated with the closed end shape (302) of the one-piece composite structure (300); the location of an end pole reference axis (510) on said end face (318) to define a zero degree fiber angle (320) of said end ply; and The method of claim 8, including an end fiber angle (512) of each set of end plies relative to the end polar reference axis (510).

12. 12. The method of claim 11, wherein the end fiber angle (512) of each set of end plies is based on 180 degrees divided by the quantity of end plies in the corresponding set of end plies.

13. The method of claim 12 , wherein the number of end plies in the corresponding set of end plies includes at least one of the following: 2, 3, 4, 5, 6, 8, 9, and 10.

14. 13. The method of claim 12, wherein the end fiber angles (512) of the corresponding sets of end plies include at least one of: 90 degrees to 60 degrees, 60 degrees to 45 degrees, 45 degrees to 36 degrees, 36 degrees to 30 degrees, 30 degrees to 22.5 degrees, 22.5 degrees to 20 degrees, 20 degrees to 18 degrees, and less than 18 degrees.

15. The third design data section (212) comprises: a set of geometric dimensions (518) for a transition region surface (324) of a mandrel (314) used in an integrated toe lay-up of the strip ply and the end ply, the transition region surface (324) being associated with the transition region (306) of the one-piece composite structure (300); the location of a strip pole reference axis (504) on the strip surface (312) to define a zero degree fiber angle (316) of said strip ply; a strip fiber angle (506) of each set of strip plies relative to the strip pole reference axis (504); Identifying the strip plies (520) within each set of strip plies that extend into the transition region (306); physical dimensions for the portion of the strip plies (522) within each set of strip plies that extends into the transition region (306); the location of an end pole reference axis (510) on the end face (318) to define a zero degree fiber angle (320) of said end ply; an end fiber angle (512) of each set of end plies relative to said end pole reference axis (510); Identifying the end plies (524) within each set of end plies that extend into the transition region (306); and The method of claim 8, including physical dimensions for portions of end plies (526) in each set of end plies that extend into the transition region (306).

16. 16. The method of claim 15, wherein the strip ply extending into the transition region and the end ply extending into the transition region form a joint within the transition region.

17. 17. The method of claim 16, wherein the joints in the transition region (306) include at least one of a scarf joint, a double scarf joint, an overlap joint, a butt joint, a series of joints, a series of joints at a common longitudinal position, and a series of joints at staggered longitudinal positions.

18. The method of claim 15, wherein at least a portion of the strip ply extending into the transition region (306) overlaps at least a portion of the end ply extending into the transition region (306).

19. The method of claim 15, wherein at least a portion of the strip ply extending into the transition region (306) abuts at least a portion of the end ply extending into the transition region (306).

20. 2. The method of claim 1, wherein the at least one computing device is configured to execute a three-dimensional modeling application program in conjunction with the processing of the design data file to construct the three-dimensional model.

21. The one-piece composite structure (300) includes an elongated hollow body (304), the closed end feature (302), and a transition region (306) between the elongated hollow body (304) and the closed end feature (302), the elongated hollow body (304) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the processing (104) of the design data file (402) includes: generating (602) an elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) of the elongated hollow body (304) based on the design data file (402) defining a plurality of sets of elongated body plies for toe layup of the elongated hollow body (304); generating (604) a closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) of the closed end shape (302) based on the design data file (402) defining two or more sets of end plies for toe layup of the closed end shape (302); and 2. The method of claim 1, comprising generating a transition portion of the three-dimensional model of the transition region based on the design data file that defines integration of the strip ply and the end ply in the transition region.

22. 22. The method of claim 21, wherein the elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) includes each strip ply of each of the plurality of sets of strip plies and strip fiber direction information for each strip ply.

23. 22. The method of claim 21, wherein the closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) includes each end ply of each of the two or more sets of end plies and fiber direction information for the end of each end ply.

24. the transition portion (706) of the three-dimensional model (414, 3200, 3300, 3400) includes each strip ply of each of the plurality of sets of strip plies extending into the transition region (306) and fiber orientation information for the strips of each of the strip plies; 22. The method of claim 21, wherein the transition portion (706) of the three-dimensional model (414, 3200, 3300, 3400) includes each end ply of each of two or more sets of end plies extending into the transition region (306) and fiber direction information for an end of each of the end plies.

25. 2. The method of claim 1, wherein the at least one computing device is configured to execute an elastic modulus analysis application program in conjunction with the analysis of the three-dimensional model to determine the elastic modulus characteristics.

26. The three-dimensional model (414, 3200, 3300, 3400) of the one-piece composite structure (300) includes an elongated hollow portion (702), a closed end portion (704), and a transition portion (706) between the elongated hollow portion (702) and the closed end portion (704), the elongated hollow portion (702) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the analysis (106) of the three-dimensional model (414, 3200, 3300, 3400) analyzing (802) the elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) based on a three-dimensional representation of each strip ply of each of a plurality of sets of strip plies for toe lay-up of the elongated hollow body (304), each strip ply including fiber orientation information for the strip; analyzing (804) the closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) based on a three-dimensional representation of each end ply of each of two or more sets of end plies for a toe layup of the closed end shape (302), each end ply including end fiber orientation information; and 2. The method of claim 1, comprising analyzing the transition portion of the three-dimensional model based on a three-dimensional representation of each strip ply extending into the transition region and each end ply extending into the transition region.

27. The analysis (802) of the elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) comprises: Dividing (902) the elongated hollow portion (702) into a plurality of lateral elongated body slices (708); dividing (904) each lateral strip slice (708) into a plurality of core samples (710) extending from the strip surface (312) through the thickness of the hollow strip portion (702); and 27. The method of claim 26, comprising analyzing (906) each core sample (710) of each lateral elongate slice (708) to determine the fiber orientation of the collective elongate of the corresponding core sample (710) and to determine the elastic modulus characteristics (418) of said core sample (710) relative to adjacent core samples (710).

28. The analysis (804) of the closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) comprises: dividing (1002) the closed end portion (704) into a plurality of lateral end slices (712); dividing (1004) each lateral end slice (712) into a plurality of core samples (714) extending from the end face (318) through the thickness of the closed end portion (704); and 27. The method of claim 26, comprising analyzing (1006) each core sample (714) of each lateral end slice (712) to determine the fiber orientation of the collective end of the corresponding core sample (714) and to determine the modulus of elasticity characteristics (418) of said core sample (714) relative to adjacent core samples (714).

29. The analysis (806) of the transition portion (706) of the three-dimensional model (414, 3200, 3300, 3400) comprises: Dividing (1102) the transition portion (706) into a plurality of lateral transition region slices (716); Dividing (1104) each lateral fiber region slice (716) into a plurality of core samples (718) extending from the transition region surface (324) through the thickness of the transition portion (706); and 27. The method of claim 26, comprising analyzing (1106) each core sample (718) of each lateral transition region slice (716) to determine the fiber orientation of the collective transition region of the corresponding core sample (718) and to determine the elastic modulus characteristics (418) of said core sample (718) relative to adjacent core samples (718).

30. the three-dimensional model (414, 3200, 3300, 3400) of the one-piece composite structure (300) includes an elongated hollow portion (702), a closed end portion (704), and a transition portion (706) between the elongated hollow portion (702) and the closed end portion (704), the elongated hollow portion (702) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the generation (108) of the modulus of elasticity result data (420) is performed by: generating (1202) modulus of elasticity result data (420) for the elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) based on modulus of elasticity characteristics (418) from an analysis of the toe layup design (200) for the elongated hollow portion (702); generating (1204) modulus result data (420) for the closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) based on modulus characteristics (418) from an analysis of the toe layup design (200) for the closed end portion (704); and 2. The method of claim 1, comprising generating elastic modulus result data for the transition portion of the three-dimensional model based on elastic modulus characteristics from an analysis of the toe layup design for the transition portion.

31. The generating (1202) of the elastic modulus result data (420) of the elongated hollow portion (702) comprises: disposing (1302) the elastic modulus result data (420) of the hollow elongated strip (702) into a plurality of lateral strip slices (708) and a plurality of core samples (710) following the circumference of corresponding lateral strip slices (708), the core samples (710) extending from a strip surface (312) through a thickness of the hollow elongated strip (702); 31. The method of claim 30, wherein the elastic modulus result data (420) for each core sample (710) includes the fiber direction of the collective elongated body of the corresponding core sample (710) and the elastic modulus characteristics (418) of the core sample (710) relative to adjacent core samples (710).

32. The generating (1202) of the elastic modulus result data (420) of the elongated hollow portion (702) comprises: generating (1304) at least one of a tabular report, a graph, and a heat map for at least one elongate slice (708) of the elongate hollow portion (702); and 32. The method of claim 31, further comprising generating (1306) at least one of a tabular report, a graph, and a heat map for the hollow elongated portion (702).

33. The generating (1204) of the elastic modulus result data (420) for the closed end portion (704) comprises: disposing (1402) the elastic modulus result data (420) of the closed end portion (704) into a plurality of lateral end slices (712) and a plurality of core samples (710) following the circumference of corresponding lateral end slices (712), the core samples (710) extending from an end face (318) through a thickness of the closed end portion (704); 31. The method of claim 30, wherein the modulus result data (420) for each core sample (710) includes a fiber direction of the collective end of the corresponding core sample (710) and the modulus characteristics (418) of the core sample (710) relative to adjacent core samples (710).

34. The generating (1204) of the elastic modulus result data (420) for the closed end portion (704) comprises: generating (1404) at least one of a tabular report, a graph (3002), and a heat map (3004) for at least one lateral end slice (712) of the closed end portion (704); and 34. The method of claim 33, further comprising generating (1406) at least one of a tabular report and a heat map (2900, 3102) for the closed end portion (704).

35. The generating (1206) of the modulus of elasticity result data (420) for the transition section (706) comprises: disposing (1502) the modulus of elasticity result data (420) of the transition portion (706) into a plurality of lateral transition region slices (716) and a plurality of core samples following the circumference of corresponding lateral transition region slices (716), the core samples (710) extending from a transition region surface (324) through a thickness of the transition portion (706); 31. The method of claim 30, wherein the modulus result data (420) for each core sample includes the fiber direction of the collective transition region of the corresponding core sample and the modulus characteristics (418) of the core sample relative to adjacent core samples.

36. The generating (1206) of the modulus of elasticity result data (420) for the transition section (706) comprises: generating (1504) at least one of a tabular report, a graph (3104, 3106), and a heat map (2900, 3102) for at least one lateral transition region slice (716) of the transition portion (706); and 36. The method of claim 35, further comprising generating (1506) at least one of a tabular report and a heat map (2900, 3102) for the transition portion (706).

37. storing (1602) said modulus result data (420) in a data storage device (422) accessible to said at least one computing device (410); printing (1604) the modulus result data (420) on a printing device (424) accessible to the at least one computing device (410); displaying (1606) the modulus result data (420) on a display device (426) accessible to the at least one computing device (410); and 16. The method of claim 1, further comprising at least one of: sending a message to an operator associated with the at least one computing device providing notification that the modulus results data is available and instructions for accessing the modulus results data.

38. 1. A method (1700) for analyzing a toe layup design (200) of a one-piece composite structure (300) having a closed end geometry (302), comprising: selecting (1702) a design data file (402) for the toe layup design (200) of the one-piece composite structure (300) having the closed end shape (302) from a design data file repository (404); constructing (1704) a three-dimensional model (414, 3200, 300, 3400) of the integrated composite structure (300); analyzing (1706) the three-dimensional model (414, 3200, 3300, 3400) with at least one computing device (410) to evaluate a modulus of elasticity characteristic (418) of the toe layup design (200); and generating (1708), at the at least one computing device (410), based on the analysis (1706) of the three-dimensional model (414, 3200, 3300, 3400), modulus result data (420) reflecting the modulus characteristics (418) of the toe layup design (200) of the integrated composite structure (300).

39. determining (2402) a first measure of goodness for the modulus of elasticity result data (420) based on the design data file (402); repeating (2404) the selecting (1702), constructing (1704), analyzing (1706), and generating (1708) for a second tow layup design of the one-piece composite structure (300) and the second design data file to generate second modulus of elasticity result data based on the second design data file; determining 2406 a second measure of goodness for the second modulus of elasticity result data based on the second design data file; comparing the second measure of goodness to the first measure of goodness (2408); and 40. The method of claim 38, further comprising: selecting (2410) an optimized toe layup design for the one-piece composite structure (300) from the toe layup design (200) and the second toe layup design based on the comparing (2408).

40. The one-piece composite structure (300) includes an elongated hollow body (304), the closed end feature (302), and a transition region (306) between the elongated hollow body (304) and the closed end feature (302), the elongated hollow body (304) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the design data file (402) includes: a first design data section (204) defining a plurality of sets of elongated body plies for toe layup of said elongated hollow body (304); a second design data section (208) defining two or more sets of end plies for toe layup of the closed end shape (302); and 40. The method of claim 38, including a third design data section (212) defining integration of the strip ply and the end ply at the transition region (306).

41. 40. The method of claim 38, further comprising executing (1802) a three-dimensional modeling application program (412) on the design data file (402) using the at least one computing device (410) in conjunction with the building (1704) of the three-dimensional model (414, 3200, 3300, 3400).

42. The one-piece composite structure (300) includes an elongated hollow body (304), the closed end feature (302), and a transition region (306) between the elongated hollow body (304) and the closed end feature (302), the elongated hollow body (304) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the execution (1704) of the three-dimensional modeling application program (412) comprises: generating (1804) an elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) of the elongated hollow body (304) based on the design data file (402) defining a plurality of sets of elongated body plies for toe layup of the elongated hollow body (304); generating (1806) a closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) of the closed end shape (302) based on the design data file (402) defining two or more sets of end plies for toe layup of the closed end shape (302); and 42. The method of claim 41, comprising generating (1808) a transition portion (706) of the three-dimensional model (414, 3200, 3300, 3400) of the transition region (306) based on the design data file (402) that defines integration of the elongate body ply and the end ply in the transition region (306).

43. 39. The method of claim 38, wherein the at least one computing device (410) is configured to execute an elastic modulus analysis application program (412) in conjunction with the analysis (1706) of the three-dimensional model (414, 3200, 3300, 3400) to determine the elastic modulus characteristics (418).

44. The three-dimensional model (414, 3200, 3300, 3400) of the one-piece composite structure (300) includes an elongated hollow portion (702), a closed end portion (704), and a transition portion (706) between the elongated hollow portion (702) and the closed end portion (704), the elongated hollow portion (702) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the analysis (1706) of the three-dimensional model (414, 3200, 3300, 3400) reveals: analyzing (1902) the elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) based on a three-dimensional representation of each strip ply of each of a plurality of sets of strip plies for toe lay-up of the elongated hollow body (304), each strip ply including strip fiber orientation information; analyzing (1904) the closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) based on a three-dimensional representation of each end ply of each of two or more sets of end plies for a toe layup of the closed end shape (302), each end ply including end fiber orientation information; and 39. The method of claim 38, comprising analyzing the transition portion of the three-dimensional model based on a three-dimensional representation of each strip ply extending into the transition region and each end ply extending into the transition region.

45. the three-dimensional model (414, 3200, 3300, 3400) of the one-piece composite structure (300) includes an elongated hollow portion (702), a closed end portion (704), and a transition portion (706) between the elongated hollow portion (702) and the closed end portion (704), the elongated hollow portion (702) extending longitudinally along an x-axis (308) and a circumference defining a y-direction (310), and the generation (1708) of the modulus of elasticity result data (420) is performed by: generating (2002) modulus of elasticity result data (420) for the elongated hollow portion (702) of the three-dimensional model (414, 3200, 3300, 3400) based on modulus of elasticity characteristics (418) from an analysis of the toe layup design (200) for the elongated hollow portion (702); generating (2004) modulus of elasticity result data (420) for the closed end portion (704) of the three-dimensional model (414, 3200, 3300, 3400) based on modulus of elasticity characteristics (418) from an analysis of the toe layup design (200) for the closed end portion (704); and 39. The method of claim 38, comprising generating (2006) modulus of elasticity result data (420) for the transition portion (706) of the three-dimensional model (414, 3200, 3300, 3400) based on modulus of elasticity characteristics (418) from an analysis of the toe layup design (200) for the transition portion (706).

46. storing (2102) said modulus result data (420) in a data storage device (422) accessible to said at least one computing device (410); printing (2104) the modulus result data (420) on a printing device (424) accessible to the at least one computing device (410); displaying (2106) the modulus result data (420) on a display device (426) accessible to the at least one computing device (410); and 39. The method of claim 38, further comprising at least one of: sending (2108) a message to an operator associated with the at least one computing device (410) providing notification that the modulus results data (420) is available and instructions for accessing the modulus results data (420).

47. 1. A method for analyzing a toe layup design (200) of a one-piece composite structure (300) having a closed end geometry (302), comprising: selecting (2202) a design data file (402) for the toe layup design (200) of the one-piece composite structure (300) having the closed end shape (302) from a design data file repository (404); processing (2204) the design data file (402) on at least one computing device (410) to construct a three-dimensional model (414, 3200, 3300, 3400) of the integrated composite structure (300); analyzing (2206) the three-dimensional model (414, 3200, 3300, 3400) with the at least one computing device (410) to evaluate a modulus of elasticity characteristic (418) of the toe layup design (200); generating, at the at least one computing device, modulus result data reflecting the modulus characteristics of the toe layup design of the integrated composite structure based on the analysis of the three-dimensional model; and 22. The method of claim 21, further comprising: performing at least one of: (i) storing the modulus of elasticity result data (420) on a data storage device (422) accessible to the at least one computing device (410); (ii) printing the modulus of elasticity result data (420) on a printing device (424) accessible to the at least one computing device (410); (iii) displaying the modulus of elasticity result data (420) on a display device (426) accessible to the at least one computing device (410); and (iv) sending a message to an operator associated with the at least one computing device (410) providing notification that the modulus of elasticity result data (420) is available and instructions for accessing the modulus of elasticity result data (420).

48. determining (2502) a first measure of goodness for the modulus of elasticity result data (420) based on the design data file (402); repeating (2504) the selecting (2202), the processing (2204), the analyzing (2206), and the generating (2208) for a second tow layup design of the one-piece composite structure (300) and the second design data file to generate second modulus of elasticity result data based on the second design data file; determining 2506 a second measure of goodness for the second modulus of elasticity result data based on the second design data file; comparing the second measure of goodness to the first measure of goodness (2508); and 48. The method of claim 47, further comprising selecting (2510) an optimized toe layup design for the one-piece composite structure (300) from the toe layup design (200) and the second toe layup design based on the comparing (2508).

49. 48. The method of claim 47, wherein the at least one computing device (410) is configured to execute a three-dimensional modeling application program (412) in conjunction with the processing (2206) of the design data file (402) to construct the three-dimensional model (414, 3200, 3300, 3400).

50. 48. The method of claim 47, wherein the at least one computing device (410) is configured to execute an elastic modulus analysis application program (412) in conjunction with the analysis (2208) of the three-dimensional model (414, 3200, 3300, 3400) to determine the elastic modulus characteristics (418).

51. The first set of end plies in the design data file (402) comprises: a first end ply having a first physical characteristic; a second end ply having a second physical property different from the first physical property; a third end ply having a third physical property different from the second physical property; and 48. The method of claim 47, including a fourth end ply having a fourth physical property different from the third physical property.

52. 52. The method of claim 51, wherein a fiber angle from the first end ply to the fourth end ply has an average of 45 degrees.

53. The first set of end plies comprises:

52. The method of claim 51, further comprising a fifth end ply having a fifth physical property different from the fourth physical property.

54. 54. The method of claim 53, wherein the fiber angle from the first end ply to the fifth end ply has an average of 36 degrees.

55. The first set of end plies comprises:

54. The method of claim 53, further comprising a sixth end ply having a sixth physical property different from the fifth physical property.

56. 56. The method of claim 55, wherein the fiber angle from the first end ply to the sixth end ply has an average of 30 degrees.

57. The first set of end plies comprises: a seventh end ply having a seventh physical property different from the sixth physical property; and 56. The method of claim 55, further comprising an eighth end ply having an eighth physical property different from the seventh physical property.

58. 58. The method of claim 57, wherein the fiber angle from the first end ply to the eighth end ply has an average of 22.5 degrees.

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