A general global-local modelling framework for the deterministic optimisation of composite structures

This work deals with the multi-scale optimisation of composite structures by adopting a general global-local (GL) modelling strategy to assess the structure responses at different scales. The GL modelling approach is integrated into the multi-scale two-level optimisation strategy (MS2LOS) for composite structures. The resulting design strategy is, thus, called GL-MS2LOS and aims at proposing a very general formulation of the design problem, without introducing simplifying hypotheses on the laminate stack and by considering, as design variables, the full set of geometric and mechanical parameters defining the behaviour of the composite structure at each pertinent scale. By employing a GL modelling approach, most of the limitations of well-established design strategies, based on analytical or semi-empirical models, are overcome. The GL-MS2LOS makes use of the polar formalism to describe the anisotropy of the composite at the macroscopic scale (where it is modelled as an equivalent homogeneous anisotropic plate). In this work, deterministic algorithms are exploited during the solution search phase. The challenge, when dealing with such a design problem, is to develop a suitable formulation and dedicated operators, to link global and local models physical responses and their gradients. Closed-form expressions of structural responses gradients are rigorously derived by taking into account for the coupling effects when passing from global to local models. The effectiveness of the GL-MS2LOS is proven on a meaningful benchmark: the least-weight design of a cantilever wing subject to different design requirements. Constraints include maximum allowable displacements, maximum allowable strains, blending, manufacturability requirements and buckling factor.