基于铺层设计特征的碳纤维增强复合材料悬架控制臂结构优化

基于铺层设计特征,提出一种使用碳纤维复合材料对承载结构件进行结构优化设计的方法和流程.该方法综合考虑结构几何特征、材料铺层方式、铺层厚度及铺层角度在设计环节中的序列关系,通过几何设计空间构建、离散变量多目标优化、基于工艺可行性的最优决策等方法实现结构设计.以碳纤维增强复合材料悬架控制臂的轻量化设计为例:首先,以钢质控制臂结构为参考建立复合材料控制臂的几何设计空间;然后,以复合材料铺层便利性为原则对其进行结构设计,采用准各向同性铺层对控制臂的铺层厚度进行设计;进而,以提高控制臂刚度和1阶固有频率为目标,使用优化算法对铺层角度进行多目标优化设计;最后,以工艺可行性为约束对优化结果进行筛选并最终完成结构设计.结果表明,所设计复合材料结构具有更大的刚度和1阶固有频率,并且与钢质结构相比减重47.9%.所提出的方法能够较好地兼顾结构特征和复合材料设计要求之间的关系,为复合材料结构优化设计理论与方法的发展提供有益参考.     

基于几何因子的复合材料气动弹性剪裁设计

实现了基于几何因子的复合材料层合板建模,解决了几何因子与Natran的参数输入问题,并根据工艺约束中的最小铺层比例对几何因子可行空间进行了推导补充。在此基础上,提出了一种基于几何因子和Nastran的复合材料气动弹性剪裁优化设计方法。首先以总厚度和几何因子作为设计变量以及以Nastran作为求解器,以强度、刚度、颤振和发散速度以及几何因子相关性约束作为约束条件进行结构寻优,得到最优的铺层总厚度和几何因子。其次,以最优几何因子作为目标,进行铺层结构逆问题求解,约束条件为复合材料铺层工艺约束。因几何因子为铺层厚度和铺层顺序的表达式,与传统的多级优化相比,以几何因子作为设计变量可以避免铺层厚度和铺层顺序的解耦,进而获得更大的设计空间,且得到的铺层结构可以满足工艺约束。最后,对一矩形悬臂复合材料层合板进行剪裁设计,使得铺层结构满足气动弹性约束且质量最小。结果显示,运用该优化方法可以得到质量更小且满足工艺约束的铺层结构。     

车用CFRP油底壳的结构与制造工艺并行优化设计

为实现碳纤维增强复合材料（carbon fiber reinforced polymer,CFRP）油底壳的替代与制造,结合复合材料铺层可制造性分析软件FiberSim与铺层结构优化模块Optistruct,对CFRP油底壳开展了结构与制造工艺并行优化设计。参照CFRP壳体类零件的成型过程,采用FiberSim软件制定了满足制造工艺要求的CFRP油底壳铺覆方案。并在此基础上,分别以CFRP油底壳刚度最大、质量最小为优化目标,以振动模态、制造工艺要求为约束,采用Optistruct模块对CFRP油底壳的铺层结构进行优化设计。经仿真分析验证,制造工艺调整后的CFRP油底壳满足各项替代要求,且CFRP油底壳的质量较原金属油底壳减小了56.7%。所提出的结构与制造工艺并行优化设计方法可较好地兼顾结构特征、复合材料设计及制造工艺要求,为复合材料产品的优化设计提供了参考。     

复合材料支撑机翼撑杆位置与结构综合优化设计

针对复合材料支撑机翼,发展了一种撑杆位置和结构综合优化设计的方法。在两种严重设计载荷状态下,考虑气动弹性效应和复合材料铺层结构的不确定性,以结构质量最小化为目标,以翼尖垂直变形、翼尖扭角、撑杆屈曲稳定性、颤振速度和强度要求为约束,在一个优化过程中实现了撑杆位置和结构参数的同步优化设计和鲁棒优化设计。结果表明,翼尖垂直变形和颤振速度要求对于撑杆位置影响明显,最优的撑杆展向位置都靠近翼根一侧,同时撑杆的总体稳定性成为同步优化设计的关键约束。鲁棒优化设计得到的撑杆位置和结构参数的最优组合对铺层结构的不确定性摄动具有良好的抗干扰性,鲁棒优化得到的最优撑杆位置会随着设计变量摄动范围而变化,翼尖垂直变形成为鲁棒优化设计的关键约束。     

基于遗传算法的复合材料结构-声辐射优化研究

研究了外载荷作用下的复合材料结构振动响应和声辐射问题。在此基础上, 分析了复合材料的结构-声辐射优化设计模型, 基于遗传算法进行了对称型复合材料板结构的结构-声辐射铺层几何优化分析。数值算例表明, 复合材料板结构的铺层数、 铺层厚度和铺层角度等参数优化, 可以有效降低结构的振动和声辐射。数值算例结果验证了优化方法的有效性。     

复合材料层合板屈曲稳定性优化设计及其灵敏度计算方法

笔者在有限元分析基础上研究了以屈曲稳定性作为约束条件或优化目标的复合材料层合板结构优化设计及其灵敏度分析方法,重点讨论了屈曲临界荷载灵敏度对内力场和载荷的依赖关系及其在铺层优化、尺寸优化和形状优化问题中的不同计算方法,并在JIFEX软件中实现了复杂结构复合材料层合板优化设计方法。数值算例验证了本文算法和程序的有效性。     

考虑气动弹性约束的复合材料支撑机翼优化设计

基于遗传-敏度混合算法对复合材料支撑机翼开展考虑气动弹性约束的优化设计,并与常规机翼构型进行比较。在严重载荷状态下,以结构质量最小化为目标,以翼尖变形、屈曲稳定性和颤振速度为约束,设计复合材料机翼铺层和支撑结构参数,并研究不同支撑点位置对于优化设计结果的影响。结果表明,复合材料支撑机翼构型能大幅减少弯曲方向上的铺层材料,有明显的减重优势。支撑点位置对于结构质量、屈曲稳定性和扭转刚度分布有较大影响,支撑结构的屈曲破坏在复合材料支撑机翼的结构设计中要引起重视。     

采用等效有限元模型的复合材料机翼结构优化

在机翼设计过程中,将等效有限元模型(EFEM)方法应用于考虑静力学和动力学要求的机翼结构优化。提出了"三步走"的结构优化策略,将一个多变量的复杂优化问题转换为一系列少变量的简单优化问题,对某支线客机的复合材料机翼进行了优化设计。首先以位移、静强度和颤振速度作为约束条件对机翼复合材料铺层比例进行优化;然后以静强度和结构稳定性作为约束,以最小化结构质量和结构效率作为优化目标,对各翼肋之间的加强壁板进行优化设计;最后再以位移和颤振速度为约束,对机翼结构总体刚度进行优化设计。结果表明:EFEM方法具有快速建模和计算量少的优点,采用"三步走"优化策略具有更高的效率,适用于初步机翼结构优化设计。     

复合材料壁板铺层参数对大展弦比机翼气动弹性优化的影响

开展了大展弦比复合材料机翼气动弹性综合优化设计研究,以复合材料层合板铺层厚度为设计变量,以多种气动弹性约束与强度/应变约束为限制条件对结构进行优化设计,从铺层比例和铺层非均衡两方面分析了蒙皮铺层参数的影响。研究表明: 在满足综合约束的条件下,随着0°铺层比例的增加,翼尖变形略微减小,颤振速度略有下降,副翼效率变化不大; 蒙皮铺层非均衡程度主要影响机翼静气动弹性能,随着蒙皮非均衡引起的机翼刚轴绕翼根向前缘逐渐偏转,翼尖垂直变形变化不明显,但翼尖负扭转变形的绝对值加大,副翼效率下降。     

基于遗传算法的大型风机复合材料叶片根部强度优化设计

为了提高复合材料叶片承担载荷的能力, 尤其是承受最大弯矩的叶片根部的承载能力, 研究了遗传算法的优化原理并将遗传算法应用到复合材料叶片根部铺层的优化设计中。针对复合材料层压结构遗传算法优化设计中, 层压结构参数具有离散型的特点, 提出了适合复合材料层压结构遗传算法优化设计的整数编码策略, 以整数来表征层压结构参数。在分析层压结构强度的基础上, 针对结构强度优化的目标构造了可用于遗传算法的适应度函数。同时参考了一定的铺层规则, 在铺层角度限制为工程中常用的四种角度的前提下, 应用遗传算法对叶片根部进行了铺层优化设计。结果表明, 由于遗传算法特有的处理离散型问题的优势, 在叶片根部的铺层优化设计中应用遗传算法是可行和可信的。     

Stacking sequence optimization to maximize the buckling load of blade-stiffened panels with strength constraints using the iterative fractal branch and bound method

Laminated carbon fiber reinforced polymer (CFRP) composites have widespread applications in aerospace structures, and thus optimization of the stacking sequences in these composites is indispensable. Here, a fractal branch and bound method (FBB) is proposed for optimizing the stacking sequences. This method requires only low computational costs, and an optimal result can be obtained rapidly by means of the deterministic process. For practical stacking sequence optimizations, more than two laminates have to be optimized, because a practical aerospace structural component usually comprises a panel and stiffeners made from composite laminates. Since the stacking sequences of the skin panel and stiffeners affect the buckling load of the stiffened panel, the optimization of both laminates must be performed simultaneously. In the present study, a new method to implement a strength constraint for the FBB method is proposed for the simultaneous optimization of more than two laminates (such as a panel and stiffeners). Moreover, a quadratic polynomial objective function, which includes lamination parameter variables of the two laminates: the stiffeners and the panel, is adopted. The strength constraint is implemented by means of a response surface. The new method is applied to the buckling load maximization of a blade-stiffened composite panel, in which the strength constraint is demonstrated as a feasibility study. The method successfully obtained optimal stacking sequences with the strength constraint at low computational cost.     

Optimum design of truss structures undergoing large deflections subject to a system stability constraint

A structural optimization algorithm is developed for shallow trusses undergoing large deflections subject to a system stability constraint. The method combines the non‐linear buckling analysis, through displacement control technique, with the optimality criteria approach. Four examples illustrate the procedure and allow the results obtained to be compared with those in the literature. It is shown that a design based on the generalized eigenvalue problem (linear buckling) highly underestimates the optimum mass for these types of structures so a design based on the linear buckling analysis can result in catastrophic failure. In one of the design examples the stresses in the elements, in the optimum design, exceed the allowable stresses, pointing out the need for a design that accounts for both non‐linear buckling and stress constraints. Copyright © 2000 John Wiley & Sons, Ltd.     

Optimization of laminated composites subject to uncertain buckling loads

Optimal design of composite laminates under buckling load uncertainty is presented. The laminates are subjected to biaxial compressive loads and the buckling load is maximized under worst case in-plane loading which is computed using an anti-optimization approach. The magnitudes of the in-plane loads are not known a priori resulting in load uncertainty subject to the only constraint that the loads belong to a given uncertainty domain. Results are given for continuous and discrete fibre orientations which constitute the optimization problem coupled to load anti-optimization problem leading to a nested solution method. It is observed that the stacking sequence of a laminate designed for a deterministic load case only differs considerably from that of a robust laminate designed taking load uncertainties into account. Consequently the buckling load carried by a deterministic design is considerably less than the one carried by a robust design when both are subjected to uncertain loads.     

Post‐buckling optimization of composite structures using Koiter's method

Thin‐walled structures, when compressed, are prone to buckling. To fully utilize the capabilities of such structures, the post‐buckling response should be considered and optimized in the design process. This work presents a novel method for gradient‐based design optimization of the post‐buckling performance of structures. The post‐buckling analysis is based on Koiter's asymptotic method. To perform gradient‐based optimization, the design sensitivities of the Koiter factors are derived, and new design optimization formulations based on the Koiter factors are presented. The proposed optimization formulations are demonstrated on a composite square plate and a curved panel where the post‐buckling stability is optimized. Copyright © 2016 John Wiley & Sons, Ltd.     

Reliability analysis of laminated composite structures using finite elements and neural networks

Saving of computer processing time on the reliability analysis of laminated composite structures using artificial neural networks is the main objective of this work. This subject is particularly important when the reliability index is a constraint in the optimization of structural performance, because the task of looking for an optimum structural design demands also a very high processing time. Reliability methods, such as Standard Monte Carlo (SMC), Monte Carlo with Importance Sampling (MC–IS), First Order Reliability Method (FORM) and FORM with Multiple Check Points (FORM–MCPs) are used to compare the solution and the processing time when the Finite Element Method (FEM) is employed and when the finite element analysis (FEA) is substituted by trained artificial neural networks (ANNs). Two ANN are used here: the Multilayer Perceptron Network (MPN) and the Radial Basis Network (RBN). Several examples are presented, including a shell with geometrically non-linear behavior, which shows the advantages using this methodology.     

Optimum buckling design of composite stiffened panels using ant colony algorithm

Optimal design of laminated composite stiffened panels of symmetric and balanced layup with different number of T-shape stiffeners is investigated and presented. The stiffened panels are simply supported and subjected to uniform biaxial compressive load. In the optimization for the maximum buckling load without weight penalty, the panel skin and the stiffened laminate stacking sequence, thickness and the height of the stiffeners are chosen as design variables. The optimization is carried out by applying an ant colony algorithm (ACA) with the ply contiguous constraint taken into account. The finite strip method is employed in the buckling analysis of the stiffened panels. The results shows that the buckling load increases dramatically with the number of stiffeners at first, and then has only a small improvement after the number of stiffeners reaches a certain value. An optimal layup of the skin and stiffener laminate has also been obtained by using the ACA. The methods presented in this paper should be applicable to the design of stiffened composite panels in similar loading conditions.     

Optimum design of laminated fibre composite plates

A method is presented for the minimum weight optimum design of laminated fibre composite plates, subject to multiple inplane loading conditions, which includes stiffness, strength and elastic stability constraints. The buckling analysis is based on an equivalent orthotropic plate approach leading to two uncoupled eigenproblems per load condition. Overall computational efficiency is achieved by using constraint deletion techniques in conjunction with Taylor series approximations for the constraints retained. The optimization algorithm used, namely the method of inscribed hyperspheres, is a sequence of linear programs technique which exhibits rapid convergence in this application. Several example problems are given to demonstrate that the method presented offers an efficient and practical optimum design procedure for the fundamental and recurring problem treated.