Title: EFFECTS OF DEFECTS ANALYSIS AND SIZING FRAMEWORK FOR EFFICIENT DESIGN OF COMPOSITE STRUCTURES

Authors: August Noevere

DOI: 10.33599/nasampe/s.23.0100

Abstract: Design of large composite structures requires striking a balance between permitted flaw size, strength margins, weight, and production rate. Stringent requirements manufacturing flaws can result in a lightweight structure because the strength properties are assumed to be closer to pristine. However, these stringent requirements can lead to production delays due to increased inspection and rework needed during the layup and rejection of parts after cure. Conversely, permitting larger flaws can reduce production delays, but will likely result in a heavier structure due to increased conservatism needed to maintain acceptable structural margins. The tradeoff between these criteria can vary between different structures and material systems, so the balance between manufacturing and design requirements is always a moving target. Assessment of this tradeoff requires having the ability to quickly evaluate the impact of flaw size on strength margin across an entire structure for a large number of load cases. The approach taken in this work is to implement an effects of defects analysis and sizing framework within HyperX. HyperX performs optimization of composite structures; this capability has been enhanced to include structural flaw data in the margin of safety calculations performed during optimization. Both the flaw import process and analysis of flaws have been generalized such that any flaw type from any source can be considered. The resulting tool enables rapid assessment of the impact of defects both at a vehicle and part level.

References: [1] V. Giurgiutiu, Comprehensive Composite Materials II: Smart Materials and Health Monitoring of Composites. Vol 7, pg 364-381, Elsevier, 2018. [2] Z. del Rosario and R. Fenrich, AIAA Journal: When Are Allowables Conservative. Vol 59, Num 5, AIAA, 2021. [3] A. Noevere and C. Collier, Mapping Manufacturing Data for Stress Analysis of Automated Fiber Placement Structures, 2018 AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Kissimmee, FL, 2018 [4] A. Noevere and C. Collier, Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures, 2019 AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, San Diego, CA, 2019 [5] A. Noevere and C. Collier, Design for Manufacturing Tool for Automated Fiber Placement Structures – Verification and Validation, 2020 AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Orlando, FL, 2020 [6] C. Sacco, A. Radwan, A. Anderson, R. Harik, and E. Gregory, Composite Structures: Machine learning in composites manufacturing: A case study of Automated Fiber Placement inspection. Vol 250, 15. Elsevier, 2020. [7] Hutten, V., Forghani, A., Silva, P., Hickmott, C., Sreekantamurthy, T., Wohl, C., Grimsley, B., Coxon, B., Poursartip, A., A Validation Study of a Physics-based Tack Model for an Automated Fiber Placement Process Simulation, SAMPE 2019 Technical Conference and Exhibition, Charlotte, NC, 2019 [8] Bedayat, H., Roy, M., Forghani, A., Hickmott, C., Palmieri, F., Grimsley, B., Coxon, B., Fernlund, G., Poursartip, A., An Efficient Modelling Approach for Prediction of Porosity Severity in Composite Structures, SAMPE 2017 Technical Conference and Exhibition, Seattle, WA, 2017 [9] Bedayat, H., Forghani, A., Hickmott, C., Palmieri, F., Grimsley, B., Coxon, B., Fernlund, G., Poursartip, A., Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and their Effect on Porosity, SAMPE 2018 Technical Conference and Exhibition, Long Beach, CA, 2018 [10] Hickmott, C., Forghani, A., Hutten, V., Lorbiecki, E., Palmieri, F., Grimsley, B., Coxon, B., Fernlund, G., Poursartip, A., A Numerical and Experimental Approach for Modeling Porosity Due to Entrapped Air and Volatiles Off-gassing During Manufacturing of Composite Structures, SAMPE 2019 Technical Conference and Exhibition, Charlotte, NC, 2019 [11] S. Joglekar, M. Pankow, and V. Ranatunga, Simulation of BVID and CAI Strength of Carbon Fiber Reinforced Composite Laminates, Proceedings of the American Society for Composites, 2016. [12] A. Noevere and C. Collier, Verification and Validation of Integrated Design and Manufacturing Analysis Tool for AFP Structures, SAMPE Conference Proceedings, 2020 [13] A. Brasington, C. Smith, J. Halbritter, R. Wehbe, and R. Harik, Surrogate Based Methods for Rapid Starting Point Optimization in Automated Fiber Placement, SAMPE Conference Proceedings, Charlotte, NC, 2022

Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000100

Pages: 10

Price: $20.00