Cost/weight optimization of composite prepreg structures for best draping strategy

• Published in: Composites. Part A, Applied science and manufacturing Applied science and manufacturing, 2010-04, Vol.41 (4), p.464-472
• Main Authors: Kaufmann, M., Zenkert, D., Åkermo, M.
• Format: Article
• Language: English
• Subjects: Applied sciences; C. Finite element analysis (FEA); Cost/Weight Optimization; E. Lay-up (manual/automated); E. Prepreg; Exact sciences and technology; Finite element analysis; Forms of application and semi-finished materials; Laminates; Lay-up (manual/automated); Maskinteknik; Mechanical engineering; Other technology; Polymer industry, paints, wood; Prepreg; SRA - Production; SRA - Produktion; TECHNOLOGY; Technology of polymers; TEKNIKVETENSKAP; Övriga teknikvetenskaper
• ISSN: 1359-835X; 1878-5840; 1878-5840
• DOI: 10.1016/j.compositesa.2009.11.012

The application of hand-laid carbon fiber prepreg is very expensive from a labor perspective. Therefore the manufacturing cost should be included in the design process. In this work, we propose a novel optimization framework which contains a draping simulation in combination with a detailed cost estimation package and the calculation of the structural performance based on FE. We suggest applying the methodology in two steps. First, a draping knowledge database is generated in which combinations of seed points and reference angles are evaluated in terms of fiber angle deviation, scrap, ultrasonic cuts and material shear. Second, a cost/weight optimization framework picks the best sets of plies during the subsequent optimization. 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.