Composite Ply Blending for Stiffness Distribution
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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 that split a composite structure model into panels, determine lamination parameters and ply quantities, and optimize ply shapes and angles using an objective function to achieve desired stiffness, while considering symmetry, separation of plies, and avoidance of ply clusters, allowing for the creation of a composite structure with non-traditional layups that match traditional layups in terms of stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional composite layering methods (0, 45, -45, 90 degrees) are used, then manufacturing simplicity is maintained, but design flexibility and adaptability for non-traditional angles are limited
Solution Approach 1:
The patent changes the parameter of fiber angle from traditional discrete values (0, 45, -45, 90 degrees) to continuous non-traditional angles. This allows the composite structure to achieve desired stiffness distributions with greater design flexibility while maintaining manufacturing feasibility through automated equipment
Solution Approach 2:
The patent introduces dynamic optimization of layup sequences, where the stacking sequence is not fixed but optimized based on desired stiffness distributions. This allows adaptive selection of fiber angles and layer configurations to meet specific performance requirements while managing manufacturing complexity
2Manufacturing precision
If non-traditional fiber angles are used, then design flexibility and stiffness optimization are improved, but manufacturing complexity and potential failure modes increase
Solution Approach 1:
The patent performs preliminary optimization of the layup sequence and fiber angle selection before manufacturing. By pre-determining the optimal stacking sequence that achieves desired stiffness distributions, the system avoids trial-and-error manufacturing and reduces the risk of failure modes associated with suboptimal configurations
Solution Approach 2:
The patent incorporates feedback mechanisms where the desired stiffness distribution serves as a target that guides the optimization of fiber angles and layup sequences. The system continuously adjusts parameters to achieve the target stiffness profile, ensuring both precision and reliability
3Strength
If more layers are added to achieve desired stiffness, then structural performance is improved, but weight and manufacturing complexity increase
Solution Approach 1:
The patent changes the approach from increasing layer quantity to optimizing layer parameters (fiber angles, stacking sequences). By carefully selecting non-traditional angles and optimized sequences, the system achieves desired stiffness with fewer layers, thereby reducing weight while maintaining structural performance
Data Source
AI summary
A method and apparatus for ply blending. A desired thickness and a desired stiffness distribution for a composite structure are received. A model of the composite structure is split into a plurality of panels. Lamination parameters and a quantity of plies for each panel of the plurality of panels are determined using the desired thickness and the desired stiffness distribution for the composite structure. Ply shapes for each ply of the plurality of panels are determined using an objective function. A fiber angle is determined for each ply of the plurality of panels. Each ply of a first half of a panel of the plurality of panels has a different fiber angle value than each other ply of the first half of the panel.