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Optimisation of Composite Stuctures: Design for Cost
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.ORCID iD: 0000-0002-9744-4550
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.ORCID iD: 0000-0002-6616-2964
2011 (English)In: International Conference for Composites 21st Century: Current and Future Trends / [ed] B. Dattaguru, et al, 2011Conference paper (Other academic)
Abstract [en]

Components made in composite material can lower the weight of structures significantly. The higher production and material cost, however, require the application of novel design strategies which allow for the cost-efficient production of these components. A methodology for a combined cost/weight optimization of composite components is presented herein. The objective function is formed by a simplified form of direct operating cost, i.e. by a weighted sum of the manufacturing cost and the component weight. The parameter that governs the balance between manufacturing cost and weight is called weight penalty and incorporates the effect of fuel burn, environmental impact or contractual penalties due to overweight. In addition, a non-destructive testing model is implemented that calculates design allowables of a laminate based on ultrasonic scan parameters. In a case study, the effect of the laminate quality on the direct operating cost is discussed. It is investigated how the permissible flaw size and therefore the scan pitch of a composite laminate can influence the optimal solution in terms of cost and weight; thus, the manufacturing cost, the non-destructive testing cost and the weight of a component can be balanced by optimizing the laminate quality in an early design phase. The optimization framework also contains a draping simulation in combination with a detailed cost estimation package and the calculation of the structural performance based on FE. First, a draping knowledge database is generated in which combinations of seed points and reference angles are evaluated in terms of fibre angle deviation, scrap, ultrasonic cuts and material shear. Second, the cost/weight optimization framework picks the best sets of plies during the subsequent optimization. By means of parametric studies it is shown that the design solution strongly depends on the magnitude of the weight penalty. It is also shown that the non-destructive testing affects the cost and choice of design concept and the permissible flaw size should be altered in order to save both weight and cost. Finally, the methodology is tested by means of a curved C-spar which is designed using plain weave and unidirectional prepreg. Different objectives in the generation of the draping database lead to different design solutions.

Place, publisher, year, edition, pages
Keyword [en]
Composite Structures, Optimization, Operating Cost, Non-destructive testing, Finite element analysis
National Category
Vehicle Engineering
Research subject
SRA - Production
URN: urn:nbn:se:kth:diva-26094OAI: diva2:369914
International Conference for Composites 21st Century: Current and Future Trends, 4-7 january, Bangalore, India, 2011
TrenOp, Transport Research Environment with Novel PerspectivesXPRES - Initiative for excellence in production research

QC 20110128

Available from: 2010-11-12 Created: 2010-11-12 Last updated: 2015-05-07Bibliographically approved

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Zenkert, DanKaufmann, MarkusÅkermo, Malin
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