Abstract
Identifying residual stresses and the distortions in composite structures during the curing process plays a vital role in coming up with necessary compensations in the dimensions of mold or prototypes and having precise and optimized parts for the manufacturing and assembly of composite structures. This paper presents an investigation into process-induced shape deformations in composite parts and structures, as well as a comparison of the analysis results to finalize design parameters with a minimum of deformation. A Latin hypercube sampling (LHS) method was used to generate the required random points of the input variables. These variables were then executed with the Ansys Composite Cure Simulation (ACCS) tool, which is an advanced tool used to find stress and distortion values using a three-step analysis, including Ansys Composite PrepPost, transient thermal analysis, and static structural analysis. The deformation results were further utilized to find an optimum design to manufacture a complex composite structure with the compensated dimensions. The simulation results of the ACCS tool are expected to be used by common optimization techniques to finalize a prototype design so that it can reduce common manufacturing errors like warpage, spring-in, and distortion.
Highlights
This paper shows a study of the fundamentals of the design optimization of composite parts by considering manufacturing limitations
This paper presents a reliable engineering approach to find process-induced shape deformations using the Ansys Composite Cure Simulation (ACCS) tool, utilizing the results of its analysis to find an optimal design with the least deformation using the fundamentals of design optimization
The fundamentals of the multiobjective optimization of a complex composite structure were described while considering two objective functions: the least amount of deformation and the shear stress generated during the thermal analysis
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Composite structures have a vast range of applications in the aerospace, automobile, and energy industries. The manufacturing of composites has grown exponentially. The necessity of lightweight design and higher performance in the aerospace and motorsports industries has increased the demand for carbon fiber-reinforced polymer composite materials. Residual stresses and shape deformations are the main obstacles for high performance in a composite structure. The use of deformed components in assembly can cause higher internal stresses, which hamper a final product’s performance [1,2,3,4,5,6]
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