Optimum Structural and Manufacturing Design of a Braided Hollow Composite Part |
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Authors: | Hossein Ghiasi Larry Lessard Damiano Pasini Maxime Thouin |
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Affiliation: | (1) Department of Mechanical Engineering, McGill University, Macdonald Engineering Building, 817 Sherbrooke West, Montreal, QC, Canada, H3A 2K6 |
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Abstract: | Simultaneous material consolidation and shaping, as performed in manufacturing of composite materials, causes a strong interconnection
between structural and manufacturing parameters which makes the design process complicated. In this paper, the design of a
carbon fiber bicycle stem is examined through the application of a multi-objective optimization method to illustrate the interconnection
between structural and manufacturing objectives. To demonstrate the proposed method, a test case dealing with the design of
composite part with complex geometry, small size and hollow structure is described. Bladder-assisted Resin Transfer Molding
is chosen as the manufacturing method. A finite element model of the stem is created to evaluate the objectives of the structural
design, while a simplified 2D model is used to simulate the flow inside the preform during the injection process. Both models
are formulated to take into account the variation of fiber orientation, thickness and fiber volume fraction as a function
of braid diameters, injection pressure and bladder pressure. Finally, a multiobjective optimization method, called Normalized
Normal Constraint Method, is used to find a set of solutions that simultaneously optimizes weight, filling time and strength.
The solution to the problem is a set of optimum designs which represent the Pareto frontier of the problem. Pareto frontier
helps to gain insight into the trade-off among objectives, whose presence and importance is confirmed by the numerical results
presented in this paper. |
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