Composite Laminate Ply Blending and Stacking Sequence
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Solution Overview
Problem
Current methods for designing composite structures with non-traditional fiber angles lack efficient methods for determining layups that match desired thickness and stiffness distributions, leading to potential manufacturing issues and undesirable failure modes.
Innovation Solution
A method and apparatus for determining a composite laminate layup with non-traditional fiber angles, using lamination parameters and objective functions to optimize ply sequences and shapes, ensuring the composite structure has the same stiffness as traditional layups while minimizing ply boundary length and avoiding undesirable manufacturing results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional composite layers with four types of angles (0, 45, -45, 90 degrees) are used, then manufacturing processes are well-established and reliable, but the design flexibility and adaptability for non-traditional angles are limited
Solution Approach 1:
The patent changes the fiber angle parameter from traditional discrete values (0, 45, -45, 90 degrees) to continuous non-traditional angles. This allows optimization of composite structure performance by selecting specific angles that better match load paths, while the automated fiber placement system enables manufacturing at these non-standard angles without proportionally increasing complexity
Solution Approach 2:
The patent introduces dynamic optimization capabilities where fiber angles and ply sequences can be varied continuously across different regions of the composite structure. This dynamic approach allows the design to adapt to local stress conditions, transitioning from static traditional angles to dynamically optimized non-traditional angles based on structural requirements
2Adaptability or versatility
If non-traditional fiber angles are used to optimize performance, then design adaptability improves, but methods for determining layups that match desired thickness and stiffness distributions become insufficient
Solution Approach 1:
The patent performs preliminary optimization of ply sequences and fiber angles before manufacturing. By pre-calculating the optimal layup configuration that achieves target stiffness and thickness distributions, the system ensures that non-traditional angles are selected with precise control over the final structural properties, avoiding trial-and-error manufacturing
Solution Approach 2:
The patent implements an iterative optimization process where the actual or predicted stiffness and thickness distributions are compared against target values, and the ply sequence and fiber angles are adjusted accordingly. This feedback loop ensures that non-traditional angle selections achieve the desired manufacturing precision for stiffness and thickness control
3Ease of manufacture
If ply boundary length is minimized to reduce manufacturing complexities, then ease of manufacture improves, but the ability to achieve desired stiffness distributions may be compromised
Solution Approach 1:
The patent applies different ply configurations and fiber angles to different local regions of the composite structure based on specific stiffness requirements. Rather than using a uniform approach, the system optimizes each local area's ply boundaries and angles to achieve the desired stiffness distribution while minimizing boundaries only where structurally appropriate
Data Source
AI summary
A composite laminate is presented. The composite laminate comprises a plurality of plies having non-traditional angles. Each of the plurality of plies has a respective shape configured to minimize a total length of the ply boundary over all of the plurality of plies. The composite laminate has a stiffness equal to a desired stiffness of a traditional composite laminate.