A numerical methodology for optimizing the geometry of composite structural parts with regard to strength

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The increased use of composite materials in lightweight structures has generated the need for optimizing the geometry of composite structural parts with regard to strength, weight and cost. Most existing optimization methodologies focus on weight and cost mainly due to the difficulties in predicting strength of composite materials. In this paper, a numerical methodology for optimizing the geometry of composite structural parts with regard to strength by maintaining the initial weight is proposed. The methodology is a combination of the optimization module of the ANSYS FE code and a progressive damage modeling module. Both modules and the interface between them were programmed using the ANSYS programming language, thus enabling the implementation of the methodology in a single step. The parametric design language involves two verifications tests: one of the progressive damage model against experiments and one of the global optimization methodology performed by comparing the strength of the initial and the optimum geometry. There were made two applications of the numerical optimization methodology, both on H-shaped adhesively bonded joints subjected to quasi-static load. In the first application, the H-shaped joining profile was made from non-crimp fabric composite material while in the second from a novel fully interlaced 3D woven composite material. In the optimization of the joint’s geometry, failure in the composite material as well as debonding between the assembled parts was considered. For both cases, the optimization led to a considerable increase in joint’s strength.