Composite Ply Layout Around Inclusions in Structural Volumes
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Solution Overview
Problem
Designing and fabricating structures with multiple layers of composite material poses challenges, especially when structural enhancements like inclusions (voids or cores) are present, as they require precise distribution of layers to ensure optimal structural integrity and weight reduction.
Innovation Solution
A system and method for generating a model with multiple composite layers that account for inclusions within a structural volume by determining whether each layer's surface rests on or butts up against another surface, allowing for the appropriate distribution and combination of ply shapes to create a resultant model with layers not within inclusions, using CAD models and data processing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers of composite material are distributed to fill a structural volume containing inclusions, then structural integrity is improved and weight is reduced, but the complexity of determining layer distribution increases
Solution Approach 1:
The structural volume is divided into multiple discrete layers, with each layer being analyzed and determined independently. The system processes each layer separately to identify its interaction with inclusions, then combines these individual layer determinations to form the complete multilayer distribution. This segmentation approach manages complexity by breaking down the overall problem into manageable per-layer components while achieving the goal of optimized structural integrity and weight reduction through multiple composite layers.
2Manufacturing precision
If ply shapes are combined for layers that butt up against inclusions, then manufacturing precision is improved, but the complexity of the determination process increases
Solution Approach 1:
The system determines the interaction between each ply shape and inclusions before finalizing the layer distribution. By performing this determination in advance for each individual layer, the system identifies which plies will butt up against inclusions and prepares their shapes accordingly. This preliminary determination ensures manufacturing precision is achieved while managing process complexity through systematic advance planning of each layer's configuration.
Solution Approach 2:
The system applies different determination and combination rules to different regions of the structural volume based on local conditions. Specifically, ply shapes are treated differently depending on whether they rest on or butt up against inclusions. This localized approach allows manufacturing precision to be optimized for each specific region while maintaining overall process manageability through region-specific handling rules.
Data Source
Figure 1
Figure 2A~2B
Figure 3~4A
AI summary
Method (600), systems (100), and processes are provided for generating a model having a plurality of represented composite layers (502, 504), wherein the represented composite layers do not fill one or more inclusions (126, 208) within a structural volume (400) represented within a computer aided drafting (CAD) model (120) representing a composite part (500). The composite part can then be manufactured, based on the resultant generated model, using any manufacturing technique, including but not limited to, 3D printer, hand layup, automated layup, and other methods for distributing multiple layers of a composite material onto a laminate surface to manufacture a composite part.