Concurrent multi-scale design optimization of composite frame structures using the Heaviside penalization of discrete material model

This paper deals with the concurrent multi-scale optimization design of frame structure composed of glass or carbon fiber reinforced polymer laminates. In the composite frame structure, the fiber winding angle at the micro-material scale and the geometrical parameter of components of the frame in the macro-structural scale are introduced as the independent variables on the two geometrical scales. Considering manufacturing requirements, discrete fiber winding angles are specified for the micro design variable. The improved Heaviside penalization discrete material optimization interpolation scheme has been applied to achieve the discrete optimization design of the fiber winding angle. An optimization model based on the minimum structural compliance and the specified fiber material volume constraint has been established. The sensitivity information about the two geometrical scales design variables are also deduced considering the characteristics of discrete fiber winding angles. The optimization results of the fiber winding angle or the macro structural topology on the two single geometrical scales, together with the concurrent two-scale optimization, is separately studied and compared in the paper. Numerical examples in the paper show that the concurrent multi-scale optimization can further explore the coupling effect between the macro-structure and micro-material of the composite to achieve an ultralight design of the composite frame structure. The novel two geometrical scales optimization model provides a new opportunity for the design of composite structure in aerospace and other industries.

Shear deformable finite beam elements for composite box beams

The shear deformable thin-walled composite beams with closed cross-sections have been developed for coupled flexural, torsional, and buckling analyses. A theoretical model applicable to the thin-walled laminated composite box beams is presented by taking into account all the structural couplings coming from the material anisotropy and the shear deformation effects. The current composite beam includes the transverse shear and the restrained warping induced shear deformation by using the first-order shear deformation beam theory. Seven governing equations are derived for the coupled axial-flexural-torsional-shearing buckling based on the principle of minimum total potential energy. Based on the present analytical model, three different types of finite composite beam elements, namely, linear, quadratic and cubic elements are developed to analyze the flexural, torsional, and buckling problems. In order to demonstrate the accuracy and superiority of the beam theory and the finite beam elements developed by this study,numerical solutions are presented and compared with the results obtained by other researchers and the detailed threedimensional analysis results using the shell elements of ABAQUS. Especially, the influences of the modulus ratio and the simplified assumptions in stress-strain relations on the deflection, twisting angle, and critical buckling loads of composite box beams are investigated.