Surrogate Model Geodesic Strain Analysis for Composite Laminate Wrinkling
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Solution Overview
Problem
Existing methods for designing composite laminate parts are inefficient and costly due to the need for extensive design/build/analysis cycles and overdesigning to account for potential ply wrinkling, which can lead to parts that are heavier and more costly than necessary.
Innovation Solution
A method that uses geodesic strain analysis and surrogate modeling to predict and minimize ply wrinkling by evaluating part features early in the design process, allowing for adjustments to reduce stress concentrations without the need for iterative manufacturing trials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If full factorial design of experiments is conducted to determine how geometric features interact to cause ply wrinkling, then the accuracy of predicting ply wrinkling is improved, but the cost and time required increases significantly due to numerous design/build/analysis cycles
Solution Approach 1:
The patent performs geodesic strain analysis on parametric models during the early design stage, before finalizing the part design. This preliminary analysis identifies potential ply wrinkling issues caused by geometric features like curvatures, ply ramps, and flange angles, allowing designers to make adjustments before committing to full manufacturing cycles.
Solution Approach 2:
The patent creates simplified parametric models that replicate the essential geometric features of the composite part (curvatures, ramps, angles) without requiring full detailed design. These parametric representations allow rapid evaluation of multiple design configurations through automated geodesic strain analysis, avoiding the need for numerous physical prototypes.
2Reliability
If broad design rules are written based on perceived forming sensitivities assuming worst-case strain scenarios, then the reliability of preventing ply wrinkling is improved, but the part becomes overdesigned resulting in increased weight and cost
Solution Approach 1:
The patent applies geodesic strain analysis to identify specific localized areas where geometric features cause stress concentrations that may lead to ply wrinkling. Instead of applying conservative design rules uniformly across the entire part, the analysis pinpoints exact locations (such as specific curvature regions, ply ramp areas, or flange angle zones) that require design modification, allowing other areas to be optimized for minimal weight.
Solution Approach 2:
The patent evaluates multiple parametric representations of the part geometry, systematically varying design parameters such as curvature radii, ply ramp angles, and flange geometries. By analyzing how these parameter changes affect geodesic strain distribution, the method identifies the minimum necessary design modifications to prevent ply wrinkling, avoiding overdesign.
3Measurement precision
If parts are fully designed, reviewed, manufactured and tested to determine whether specific geometric features cause ply wrinkling, then the accuracy of identifying problematic features is improved, but the productivity and efficiency of the design process deteriorates
Solution Approach 1:
The patent performs automated geodesic strain analysis on parametric models during the conceptual and preliminary design phases, identifying problematic geometric features before final design completion. This early detection eliminates the need for post-manufacturing testing to identify ply wrinkling issues, significantly improving design process efficiency while maintaining high identification accuracy.
Data Source
AI summary
A composite laminate part such as a spar having reduced ply wrinkling is designed by generating a surrogate model of the part, and performing a geodesic strain analysis of the surrogate model. The results of the analysis are used to modify the part design to reduce strains in areas of the part that may cause ply wrinkling.