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Optimization of composite aeronautical components by Re-designing with double-double laminates.

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Title: Optimization of composite aeronautical components by Re-designing with double-double laminates.
Authors: Riccio, A.1 (AUTHOR) aniello.riccio@unicampania.it, Caprio, F. Di2 (AUTHOR), Tsai, S.W.3 (AUTHOR), Russo, A.1 (AUTHOR), Sellitto, A.1 (AUTHOR)
Source: Aerospace Science & Technology. Aug2024, Vol. 151, pN.PAG-N.PAG. 1p.
Subjects: Laminated materials, Finite element method, Stress concentration, Composite columns, Rapid tooling, Structural design, Sustainability
Abstract: • This paper proposes a new design approach for reinforced composite laminates, based on Double-Double laminates building blocks, able to reduce the structural weight of composite components and able to set the reinforcing fibres directions according to the real stress distribution in the laminate. • The proposed design approach is able to reduce the weight of composite components up to 50% with respect to the standard quad (0°/90°/−45°/45°) composite laminates by proposing design solutions which can be considered attractive from a manufacturing cost and time perspective. This paper introduces a novel approach to optimize aircraft structural design for enhanced performance and environmental sustainability. Traditional constraints on composite laminate stacking sequences, such as the symmetrical and balanced nature of classical quasi-isotropic laminates, often lead to over-dimensioning of aeronautical components. To overcome these limitations, the adoption of a new class of laminates known as Double-Double laminates, originally introduced by Prof. S.W. Tsai, is proposed. Unlike traditional laminates, Double-Double laminates offer flexibility in layer orientations, small building blocks, easy homogenization, and tapering capability. This study presents various case studies of increasing complexity to assess the effectiveness of the proposed methodology. First, a multicopter frame is redesigned to reveal the methodology's ability to reduce component weight while ensuring strength requirements under typical service loads. Then, the "DD Automated Design Tool", a newly developed Finite Element Method tool interfacing with the Lamsearch engine, is introduced. This tool facilitates the rapid identification of optimal composite double-double laminate layups based on material properties, applied loads, and boundary conditions. By iteratively interacting between the Finite Element Method software and the Lamsearch engine, the tool efficiently identifies the best laminate angles to meet specific strength requirements. To validate the weight-saving capability of the proposed methodology, the optimizations on a composite fuselage section and a real composite wing-box under realistic loading conditions have been carried out. Both cases resulted in significant weight reductions compared to initial configurations, demonstrating the effectiveness of Double-Double laminates in achieving structural efficiency and meeting performance demands. [ABSTRACT FROM AUTHOR]
Copyright of Aerospace Science & Technology is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 178463901
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Optimization of composite aeronautical components by Re-designing with double-double laminates.
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  Data: <searchLink fieldCode="AR" term="%22Riccio%2C+A%2E%22">Riccio, A.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> aniello.riccio@unicampania.it</i><br /><searchLink fieldCode="AR" term="%22Caprio%2C+F%2E+Di%22">Caprio, F. Di</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Tsai%2C+S%2EW%2E%22">Tsai, S.W.</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Russo%2C+A%2E%22">Russo, A.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sellitto%2C+A%2E%22">Sellitto, A.</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Aerospace+Science+%26+Technology%22">Aerospace Science & Technology</searchLink>. Aug2024, Vol. 151, pN.PAG-N.PAG. 1p.
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  Data: <searchLink fieldCode="DE" term="%22Laminated+materials%22">Laminated materials</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Stress+concentration%22">Stress concentration</searchLink><br /><searchLink fieldCode="DE" term="%22Composite+columns%22">Composite columns</searchLink><br /><searchLink fieldCode="DE" term="%22Rapid+tooling%22">Rapid tooling</searchLink><br /><searchLink fieldCode="DE" term="%22Structural+design%22">Structural design</searchLink><br /><searchLink fieldCode="DE" term="%22Sustainability%22">Sustainability</searchLink>
– Name: Abstract
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  Data: • This paper proposes a new design approach for reinforced composite laminates, based on Double-Double laminates building blocks, able to reduce the structural weight of composite components and able to set the reinforcing fibres directions according to the real stress distribution in the laminate. • The proposed design approach is able to reduce the weight of composite components up to 50% with respect to the standard quad (0°/90°/−45°/45°) composite laminates by proposing design solutions which can be considered attractive from a manufacturing cost and time perspective. This paper introduces a novel approach to optimize aircraft structural design for enhanced performance and environmental sustainability. Traditional constraints on composite laminate stacking sequences, such as the symmetrical and balanced nature of classical quasi-isotropic laminates, often lead to over-dimensioning of aeronautical components. To overcome these limitations, the adoption of a new class of laminates known as Double-Double laminates, originally introduced by Prof. S.W. Tsai, is proposed. Unlike traditional laminates, Double-Double laminates offer flexibility in layer orientations, small building blocks, easy homogenization, and tapering capability. This study presents various case studies of increasing complexity to assess the effectiveness of the proposed methodology. First, a multicopter frame is redesigned to reveal the methodology's ability to reduce component weight while ensuring strength requirements under typical service loads. Then, the "DD Automated Design Tool", a newly developed Finite Element Method tool interfacing with the Lamsearch engine, is introduced. This tool facilitates the rapid identification of optimal composite double-double laminate layups based on material properties, applied loads, and boundary conditions. By iteratively interacting between the Finite Element Method software and the Lamsearch engine, the tool efficiently identifies the best laminate angles to meet specific strength requirements. To validate the weight-saving capability of the proposed methodology, the optimizations on a composite fuselage section and a real composite wing-box under realistic loading conditions have been carried out. Both cases resulted in significant weight reductions compared to initial configurations, demonstrating the effectiveness of Double-Double laminates in achieving structural efficiency and meeting performance demands. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Aerospace Science & Technology is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1016/j.ast.2024.109304
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 1
        StartPage: N.PAG
    Subjects:
      – SubjectFull: Laminated materials
        Type: general
      – SubjectFull: Finite element method
        Type: general
      – SubjectFull: Stress concentration
        Type: general
      – SubjectFull: Composite columns
        Type: general
      – SubjectFull: Rapid tooling
        Type: general
      – SubjectFull: Structural design
        Type: general
      – SubjectFull: Sustainability
        Type: general
    Titles:
      – TitleFull: Optimization of composite aeronautical components by Re-designing with double-double laminates.
        Type: main
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            NameFull: Riccio, A.
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            NameFull: Caprio, F. Di
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            NameFull: Tsai, S.W.
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            NameFull: Russo, A.
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            – D: 01
              M: 08
              Text: Aug2024
              Type: published
              Y: 2024
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              Value: 151
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