Highly automated “design for manufacture” of composite components

Abstract

Design of composite components is inherently multi-disciplinary problem; the current sequential design method is not very well suited for holistic design optimization and frequent iteration through the design space. A novel methodology for comprehensive design of a composite component is suggested in this paper. The methodology utilizes python scripting to create an interconnected system of simulations (SySi) covering geometry, aerodynamic and structural performance, and methods of manufacture. An SQL database is used to manage and trace iteration data through CAD, basic aerodynamic analysis, meshing, structural FEA, kinematic braiding simulation, and resin infusion simulation. The models are self-generated with given iterated variables, to allow for multi-simulation optimisation and fast component rework.A representative aerospace part was developed to demonstrate the suggested methodology. A small UAV braided spar was selected. It is sufficiently simple for demonstrator development, yet it retains some of the complexities of a typical composite component.All the modules were successfully automated, providing a variety of standalone benefits. A Latin hypercube sampling method proved highly successful in initial sampling of the design space. It supports troubleshooting, as it generates all allowed combinations of parameters. It was also used as input information for surrogate models because other optimisation methods proved too computationally expensive.The alternative highly automated system of simulations design process was successfully demonstrated. It was shown that iteration and optimisation through multiple simulations at once is possible, and that SQL and Python are the right tools for it. The pathways towards industrial application of the design method require further study.