Design of laminates by a novel “double–double” layup

George S Springer,Tibor Czigany,Bruno Vermes,Stephen W Tsai,Thierry Massard

doi:10.1016/j.tws.2021.107954

George S Springer, Tibor Czigany + Show 3 more

Open Access

https://doi.org/10.1016/j.tws.2021.107954

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Abstract

We introduce the double–double composite layup method and highlight its advantages over the current industry standard layup method. Proof that the double–double (DD) layup method can significantly reduce the required number of plies in laminates and therefore reduce the weight of composite structures is provided. The 4-ply [±ϕ∕±ψ] sub-laminates can also make the design and manufacturing processes simpler and less prone to error compared to conventional (quad) layups. Layup homogenization that makes the novel layup method a viable option by mitigating warpage of non-symmetric laminates is also investigated both analytically and experimentally to prove its effectiveness.

Highlights

The ultimate goal with composites is to design lighter structural components without compromising strength or stiffness
Layup homogenization is an integral part of the novel double–double layup method presented in this paper, as the 4-ply building blocks of these laminates are usually asymmetric
With double–double layups, we showed that the laminate design and manufacturing processes can be simpler and less prone to error compared to those of conventional quad layups

Summary

Introduction

The ultimate goal with composites is to design lighter structural components without compromising strength or stiffness. Material design and development is more of a material and chemical engineering challenge, and the geometry of the component is often set by considerations other than just strength and stiffness (e.g. aerodynamics). It is the optimization of the internal structure – the layup – where structural engineers and designers should have the greatest freedom and potential to exploit the mechanical advantages of composites. This is the design step where engineers significantly reduce their own design freedom by following some outdated design guidelines. We present a more effective design method that can lead to lighter composite structures

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