Gant Ov Nik 2006

Laminated Composite Materials
Structural Design
Methods of Composite Optimization
Design and Optimization of Laminated

Composite Materials
Vladimir Gantovnik
Clemson University
November 14, 2006
Vladimir Gantovnik Clemson University

Design and Optimization of Laminated Composite Materials
Examples
Structural Design
Outline
1 Laminated Composite Materials

2 Structural Design
3 Methods of Composite Optimization
4 Examples

Examples
Structural Design
Composite Materials

Examples
Structural Design
Composite Materials
Combination of a strong material (fibers) with a weaker

material (matrix)

Examples
Structural Design
Composite Materials

material (matrix)
Layered structure

Examples
Structural Design
Composite Materials

material (matrix)
Layered structure
Stacking sequence
Examples
Structural Design
Composite Materials

material (matrix)
Layered structure
Stacking sequence
Directional nature of the material - Anisotropy
Examples
Structural Design
Composite Components in an Airbus A-320

Examples
Structural Design
SEM Micrographs of Carbon Fiber Composite

Examples
Structural Design
Carbon Fiber Composite Fuselage Section

Examples
Structural Design
Composite Components in Helicopter

Examples
Structural Design
Composite Components in Military Aircraft

Examples
Structural Design
SpaceShipOne
SpaceShipOne is the first operational space vehicle made entirely
of carbon composite!

Examples
Structural Design
Composite Pieces in an Vehicles

Examples
Structural Design
Composite Pieces in an Vehicles

Examples
Structural Design
Composite Bicycle

Examples
Structural Design
Structural Design and Optimization

Examples
Structural Design
Structural Design and Optimization

Galileo Galilei (1638): Optimal cantilever problem (parabolic
height function produces the minimum weight design for a
tip-loaded, constant width cantilever).

Examples
Structural Design
Optimization Problem Formulation

Standard Form:
Minimize
f (x)
subject to
gj (x) 0,
j {1, . . . , q}
and
(xi )min xi (xi )max ,
i {1, . . . , m}.

Examples
Structural Design
Optimization Problem Formulation

Standard Form:
Minimize
f (x)
subject to
gj (x) 0,
j {1, . . . , q}
and
(xi )min xi (xi )max ,
i {1, . . . , m}.
Linear (LP) and Nonlinear (NL) Programming Problems;
Integer Programming Problems (IP);
Mixed-Integer Programming Problems (MIP).
Examples
Structural Design
Optimization Methods
Mathematical programming techniques

Examples
Structural Design

For composites: Kirch (1981), Vanderplaats (1984), Rozvany
(1989), Arora (1990), Haftka (1990).

Examples
Structural Design

(1989), Arora (1990), Haftka (1990).
Evolutionary methods

Examples
Structural Design
Examples

(1989), Arora (1990), Haftka (1990).
Evolutionary methods
For composites: Callahan & Weeks (1992), Le Riche &
Haftka (1993), Hajela (1993), Nagendra et al. (1993), Ball et
al. (1993), G
urdal et al. (1994), Kogiso et al. (1994).

Structural Design
Stacking Sequence
45
z=h/2
90
h
45
0
z=0
45
90
z=-h/2

Examples
Structural Design
Examples
Stacking Sequence
45
z=h/2
90
h
45
0
z=0
45
90
z=-h/2

Possible angles: 0 , 45 ,
90
Structural Design
Examples
Stacking Sequence
45
z=h/2
90
h
45
0
Genetic code: 1,4,7

z=0
45
90
90
z=-h/2

Structural Design
Examples
Stacking Sequence
45
z=h/2
90
h
45
0
Genetic code: 1,4,7

z=0
45
90
90
z=-h/2

Laminate Code:
[90/45/0/45/90/45]
Structural Design
Examples
Stacking Sequence
45
z=h/2
90
h
45
0
Genetic code: 1,4,7

z=0
Laminate Code:
[90/45/0/45/90/45]
Integer Design Variable:
(7, 4, 1, 4, 7, 4)
45
90
90
z=-h/2

Structural Design
Examples
Typical Optimization Problems
Design of laminates with required stiffness

Optimization for maximum strength
Design for maximum buckling loads
Thermal effects \ uniform or variable temperature distribution

Structural Design
Wing with Individually Optimized Laminates

Examples
Structural Design
Integer Search Space
Number of possible designs:

`
X
`
X
3i = 3,
`=1
i=1
N i (A),
1 4 7
i=1
where A is the integer

alphabet; N(A) is the length of
the alphabet A; ` is the length
of chromosome, or number of
plies in a laminate.

`
X
3i = 12,
`=2
i=1
11 14 17 10
41 44 47 40
71 74 77 70
Examples
Structural Design
Integer Search Space

`
1
2
3
4
5
6
7
8
9
10
20
2
2
6
14
30
62
126
254
510
1022
2046
2097150
N(A)
3
4
3
4
12
20
39
84
120
340
363
1364
1092
5460
3279
21844
9840
87380
29523
349524
88572
1398100
5230176600 1466015503700

Examples
Structural Design
Selection of Variables
Material related variables

Configuration related variables
Geometry related variables

Examples
Structural Design
Selection of Variables
Material related variables

Configuration related variables
Geometry related variables
Decision variables
Design variables

Examples
Structural Design
Material Related Variables

Examples
Structural Design

Decision variables:
Fiber material

Examples
Structural Design

Decision variables:
Fiber material
Fiber pattern

Examples
Structural Design
Examples

Decision variables:
Fiber material
Fiber pattern
Continuous fibers (unidirectional, biaxial, woven fabric)
Discontinuous fibers (randomly oriented, preferred orientation)

Structural Design
Examples

Decision variables:
Fiber material
Fiber pattern
Matrix material

Structural Design
Examples

Decision variables:
Fiber material
Fiber pattern
Matrix material
Polymer
Metal
Carbon
Ceramic

Structural Design
Examples

Decision variables:
Fiber material
Fiber pattern
Matrix material
Polymer
Metal
Carbon
Ceramic
Design variables:
Fiber volume content
Concentration of fibers with respect to location
Structural Design
Configuration Related Variables

Examples
Structural Design
Decision variables:

Examples
Structural Design
Decision variables:
Selection of the type of lamination:

Examples
Structural Design
Decision variables:
Non-hybrid laminate
Hybrid laminate
Sandwich structure

Examples
Structural Design
Decision variables:
Non-hybrid laminate
Hybrid laminate
Sandwich structure
Design variables:

Examples
Structural Design
Decision variables:
Non-hybrid laminate
Hybrid laminate
Sandwich structure
Design variables:
Fiber orientation
Stacking sequence
Layer thicknesses

Examples
Structural Design
Geometry Related Variables

Examples
Structural Design
Decision variables:
Location and type of joints
Form of the centerline or the mid-surface (e.g., cylindrical,
spherical or paraboloid shells, etc.)
Cross-sectional shape (e.g., I-beam, L-beam, etc.)

Examples
Structural Design
Decision variables:
Design variables:

Examples
Structural Design
Decision variables:
Design variables:
Cross-sectional dimensions
Locations of supports
Curvature in the case of shell structures

Examples
Structural Design
Fuselage Panel

Examples
Structural Design
Stiffener

Examples
Structural Design
Examples
Composite Materials with Different Forms of Constituents

Structural Design
Fiber Arrangement Patterns in the Layer

Examples
Structural Design
Best Aircraft?

Examples
Structural Design
Best Aircraft?

Examples
Structural Design
Best Aircraft?

Examples
Structural Design
Design/Optimization Issues
Design Complexity

Examples
Structural Design
Design Complexity
Modelling complexity:
the level of complexity employed in a modelling of a structure
(laminate, stiffened plate, segmented plate, grid shell, etc.)

Examples
Structural Design
Examples
Design Complexity
Analysis complexity:
the constitutive and geometrical properties used in the
structural analysis (linear elastic analysis, plastic, nonlinear and
probabilistic effects, material, loading, and geometrical
uncertainties)

Structural Design
Examples
Design Complexity
Analysis complexity:
the constitutive and geometrical properties used in the
structural analysis (linear elastic analysis, plastic, nonlinear and
probabilistic effects, material, loading, and geometrical
uncertainties)
Optimization complexity:
the type of optimization problem (continuous design variables,
integer design variables, mixed-integer design variables,
convexity of design space, etc.)

Structural Design
Laminate under Transversal Loading

Examples
Structural Design
Laminated Plate Theory
The strain-displacement relationships:

u
,
x
v
,
=
y
u v
=
+
.
y
x
xx =
yy
xy

Examples
Structural Design
The strains in terms of middle surface displacements:

2w
u 0
z 2,
x
x
v 0
2w
=
z 2,
y
y
u 0 v 0
2w
=
+
2z
.
y
x
xy
xx =
yy
xy

Examples
Structural Design
Examples

The strains in terms of middle surface displacements:
xx 0xx
xx
0
yy
yy
=
+z
,
yy
xy
0xy
xy
where
0
xx
0yy
=
0
xy
u 0
y
u 0
x
v 0
y
v 0
x

xx
x2 2
w
yy
=
y 2
2w
xy
2 xy
Structural Design
Examples
The stresses are
xx
yy
=
xy k
0
11 Q
12 Q
16
Q
xx
xx
12 Q
22 Q
26
0yy
yy
Q
+z
,
0
66
16 Q
26 Q
Q
xy
xy
k
ij are the plane stress-reduced stiffnesses.

where Q

Structural Design
The forces
Nxx
Nyy
Nxy
and moments for a n-ply laminate:
n Z zk xx
Z h/2 xx
X
yy
yy
=
dz =
dz,
h/2
zk1
k=1
xy
xy
k
n Z zk xx
Mxx Z h/2 xx
X
Myy
yy
yy
=
z dz.
z dz =
z
h/2
k1
k=1
xy
xy k
Mxy

Examples
Structural Design
The forces for a n-ply laminate:

A11 A12
Nxx
Nyy
= A12 A22
Nxy
A16 A26
B11 B12
B12 B22
B16 B26

A16 0xx
0
A26
yy
0xy
A66
B16 xx
yy
B26
xy
B66
Examples
Structural Design
The moments for a n-ply laminate:

B11 B12
Mxx
Myy
= B12 B22
Mxy
B16 B26
D11 D12
D12 D22
D16 D26

B16 0xx
0
B26
+
yy
0
xy
B66
D16 xx
yy
D26
.
xy
D66
Examples
Structural Design
Examples

The extensional stiffness (Aij ), the coupling stiffness (Bij ), and the
bending stiffness (Dij ) are defined as
Aij =
Bij =
Dij =
n
X
ij )k (zk zk1 ),
(Q
k=1
n
X
1
2
1
3
ij )k (z 2 z 2 ),
(Q
k
k1
k=1
n
X
ij )k (z 3 z 3 ),
(Q
k
k1
k=1
ij is the reduced stiffness matrix.

where Q
Structural Design

The reduced stiffness matrix is
11 = Q11 c 4 + 2(Q12 + 2Q66 )s 2 c 2 + Q22 s 4 ,
Q
12 = (Q11 + Q22 4Q66 )c 2 s 2 + Q12 (s 4 + c 4 ),
Q
22 = Q11 s 4 + 2(Q12 + 2Q66 )s 2 c 2 + Q22 c 4 ,
Q
16 = (Q11 Q12 2Q66 )sc 3 + (Q12 Q22 + 2Q66 )s 3 c,
Q
26 = (Q11 Q12 2Q66 )s 3 c + (Q12 Q22 + 2Q66 )sc 3 ,
Q
66 = (Q11 + Q22 2Q12 2Q66 )s 2 c 2 + Q66 (s 3 + c 3 ),
Q
where s = sin(), c = cos(),
Q11,22 =
E1,2
12 E2
, Q12 =
, Q66 = G12 .
1 12 21
1 12 21

Examples
Structural Design

Equilibrium equations in terms of forces and moments:
Nxy
Nxx
+
= 0,
x
y
Nxy
Nyy
+
= 0,
x
y
2 Mxy
2 Myy
2 Mxx
2w
2w
+
2
+
+
N
+
N
+
xx
yy
x 2
xy
y 2
x 2
y 2
2w
2Nxy
= 0.
xy

Examples
Structural Design
Examples
Example
The equation governing the out-of-plane displacement w of a
symmetric and balanced laminate subjected to a pressure loading q
is
4w
4w
4w
+
4D
+
2(D
+
2D
)
+
16
12
66
x 4
x 3 y
x 2 y 2
4w
4w
4D26
+
D
= q(x, y ).
22
xy 3
y 4
D11
If we know displacement field of every point it means that we know

everything about the structure!

Structural Design
Example (out-of-plane displacement)
For a simply supported plate under sinusoidally varying pressure,

x y
q(x, y ) = q0 sin
sin
,
a
b
the solution is
w=
a4 q0 sin(x/a) sin(y /b)

.
4 [D11 + 2(D12 + 2D66 )(a/b)2 + D22 (a/b)4 ]

Examples
Structural Design
Examples
Example (out-of-plane displacement)

For a uniform pressure distribution,
q(x, y ) = q0 ,
the solution is
w=
16q0
6
m=1,3,... n=1,3,...
wmn sin
mx
a
sin
ny
b
where
wmn

mn 2
n 4 1
m 4
1
=
D11
+ 2(D12 + 2D66 )
+ D22
.
mn
a
ab
b

Structural Design
Example (transverse vibration)

For the transverse vibrations of a laminated plate, we replace q
with the inertia load
q(x, y ) = h
2w
.
t 2
The natural vibration frequencies are given as

r
m 4
n 4
mn 2
2
D11
+ 2(D12 + 2D66 )
+ D22
,
mn =
a
ab
b
h
where m and n are the number of half waves in the x and y
directions, respectively.

Examples
Structural Design
Examples
Example (buckling)
If the plate is loaded such that Nx = Nx0 and Ny = Ny 0 ,

then the critical value of corresponding to a buckling load is
determined as
h
4
2
i
n 4
+
2 D11 ma + 2(D12 + 2D66 ) mn
ab
b
.
cr (m, n) =
2
2
(m/a) Nx0 + (n/b) Ny 0
The buckling load multiplier is obtained by finding the lowest value
of cr for all combinations of m and n.

Structural Design
Future Research

Examples
Structural Design
Future Research
Remember 1466015503700 possible designs (20 layers and 4

possible orientations only!)

Examples
Structural Design
Future Research

Single ply thickness is 0.1429 mm

Examples
Structural Design
Future Research

Wall thickness in submarine is 100 mm

Examples
Structural Design
Future Research

Laminate consists of 700 layers!!!

Examples
Structural Design
Future Research

Laminate consists of 700 layers!!!
How many possible combinations?

Examples

Gant Ov Nik 2006

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Laminated Composite Materials

Methods of Composite Optimization

Design and Optimization of Laminated

November 14, 2006

Vladimir Gantovnik Clemson University

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