Ply optimization feasibility analysis for multi-layer composite parts

Patent metadata

Field	Value
Publication number	US-10322792-B2
Application number	US-201715399104-A
Country	US
Kind code	B2
Filing date	Jan 5, 2017
Priority date	Feb 8, 2016
Publication date	Jun 18, 2019
Grant date	Jun 18, 2019

Abstract

Systems and methods are provided for composite part design. One embodiment is a method for selectively analyzing feasibility of optimizing fiber orientations for layers of a multi-layer composite part subdivided into panels that each comprise a fraction of an area of the composite part. The method includes identifying stacking sequence rules that constrain the composition of sublaminates that comprise consecutively stacked layers utilized during optimization, for each panel of the composite part, analyzing the panel by identifying ply counts that constrain a number of plies at the panel, selecting a number of sublaminates to utilize during optimization of the panel, calculating ply count ranges for a laminate, based on the number of sublaminates and the stacking sequence rules, and determining whether the ply counts for the panel comply with the ply count ranges for the laminates.

First claim

The invention claimed is:

1. A method for selectively analyzing feasibility of optimizing fiber orientations for layers of a multi-layer composite part subdivided into panels that each comprise a fraction of an area of the composite part, the method comprising:
identifying stacking sequence rules which constrain the composition of sublaminates that comprise consecutively stacked layers utilized during optimization; and
for each panel of the composite part, analyzing the panel by:
identifying ply counts that constrain a number of plies at the panel, wherein the ply counts indicate numbers of plies on a fiber orientation-by-fiber orientation basis;
selecting a number of sublaminates to utilize during optimization of the panel;
calculating ply count ranges for a laminate, based on the number of sublaminates and the stacking sequence rules;
determining whether the ply counts for the panel comply with the ply count ranges for the laminate, prior to performing optimization of the panel;
in the event that the ply counts for the panel do not comply with the ply count ranges for the laminate, preemptively excluding the number of sublaminates from being utilized during the optimization; and
in the event that the ply counts for the panel do comply with the ply count ranges for the laminate, choosing the number of sublaminates for consideration for the panel during the optimization; and

performing optimization of fiber orientations for the multi-layer composite part by, for each panel:
identifying a chosen number of sublaminates for the panel;
selecting a group of sublaminates up to the chosen number for consideration during optimization of the panel; and
stacking together the selected sublaminates within the panel in an order that enhances manufacturability of the composite part.

2. The method of claim 1 further comprising:
for each of multiple numbers of sublaminates:
calculating additional ply count ranges for a laminate and determining whether the ply counts for a panel comply with the additional ply count ranges for that laminate.

3. The method of claim 2 wherein:
the report indicates numbers of sublaminates for which the ply counts for a panel comply with the ply count ranges for a laminate.

4. The method of claim 1 wherein:
there are multiple permitted numbers of sublaminates; and
the method further comprises:
preventing optimization of the composite part in response to determining that ply counts for a panel do not comply with ply count ranges for any of the permitted numbers of sublaminates.

5. The method of claim 1 further comprising:
detecting that a next panel has ply counts that are the same as ply counts for a panel that has already been analyzed, and in response to the detection;
foregoing selecting a number of sublaminates to utilize during optimization of the next panel; and
foregoing calculating ply count ranges for a laminate corresponding with the next panel.

6. The method of claim 1 wherein:
the fiber orientations are selected from the group consisting of 0°, 45°, −45°, and 90°.

7. The method of claim 1 wherein:
the stacking sequence rules define a minimum number and a maximum number of plies for a sublaminate, on a fiber orientation-by-fiber orientation basis.

8. A non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method for selectively analyzing feasibility of optimizing fiber orientations for layers of a multi-layer composite part subdivided into panels that each comprise a fraction of an area of the composite part, the method comprising:
identifying stacking sequence rules which constrain the composition of sublaminates that comprise consecutively stacked layers utilized during optimization; and
for each panel of the composite part, analyzing the panel by:
identifying ply counts that constrain a number of plies at the panel, wherein the ply counts indicate numbers of plies on a fiber orientation-by-fiber orientation basis;
selecting a number of sublaminates to utilize during optimization of the panel;
calculating ply count ranges for a laminate, based on the number of sublaminates and the stacking sequence rules; and
determining whether the ply counts for the panel comply with the ply count ranges for the laminate;
in the event that the ply counts for the panel do not comply with the ply count ranges for the laminate, preemptively excluding the number of sublaminates from being utilized during the optimization; and
in the event that the ply counts for the panel do comply with the ply count ranges for the laminate, choosing the number of sublaminates for consideration for the panel during the optimization; and

performing optimization of fiber orientations for the multi-layer composite part by, for each panel:
identifying a chosen number of sublaminates for the panel;
selecting a group of sublaminates up to the chosen number for consideration during optimization of the panel; and
stacking together the selected sublaminates within the panel in an order that enhances manufacturability of the composite part.

9. The medium of claim 8 wherein the method further comprises:
for each of multiple numbers of sublaminates:
calculating additional ply count ranges for a laminate and determining whether the ply counts for a panel comply with the additional ply count ranges for that laminate.

10. The medium of claim 9 wherein:
the report indicates numbers of sublaminates for which the ply counts for a panel comply with the ply count ranges for a laminate.

11. The medium of claim 8 wherein:
there are multiple permitted numbers of sublaminates; and
the method further comprises:
preventing optimization of the composite part in response to determining that ply counts for a panel do not comply with ply count ranges for any of the permitted numbers of sublaminates.

12. The medium of claim 8 wherein the method further comprises:
detecting that a next panel has ply counts that are the same as ply counts for a panel that has already been analyzed, and in response to the detection;
foregoing selecting a number of sublaminates to utilize during optimization of the next panel; and
foregoing calculating ply count ranges for a laminate corresponding with the next panel.

13. The medium of claim 8 wherein:
the fiber orientations are selected from the group consisting of 0°, 45°, −45°, and 90°.

14. The medium of claim 8 wherein:
the stacking sequence rules define a minimum number and a maximum number of plies for a sublaminate, on a fiber orientation-by-fiber orientation basis.

15. An apparatus comprising:
an interface that receives input indicating a geometry of a multi-layer composite part; and
a controller that generates a design for the part by subdividing the composite part into panels that each comprise a fraction of an area of the composite part, and engaging in optimization to select fiber orientations for layers of those panels,
the controller identifies stacking sequence rules that constrain the composition of sublaminates that comprise consecutively stacked layers utilized during optimization, and for each panel of the composite part, analyzes the panel by identifying ply counts that constrain a number of plies at the panel, wherein the ply counts indicate numbers of plies on a fiber orientation-by-fiber orientation basis, selects a number of sublaminates to utilize during optimization of the panel, calculates ply count ranges for a laminate, based on the number of sublaminates and the stacking sequence rules, and determines whether the ply c

Assignees

• Boeing Co

Inventors

• Thompson Richard Joel
• Blom-Schieber Adriana Willempje

Classifications

• B64F5/00

  Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for · CPC title

• G06F2113/26

  Composites · CPC title

• B32B2605/18

  Aircraft · CPC title

• G05B19/042

  using digital processors (G05B19/05 takes precedence) · CPC title

• G06F2113/28

  Fuselage, exterior or interior · CPC title