Generating realistic laminate fiber angle distributions for optimal variable stiffness laminates

The advent of advanced fiber placement technology has made it possible, through the use of fiber steering, to exploit the anisotropic properties of composite materials to a larger extent than was previously possible. Spatial variation of stiffness can be induced by steering composite fibers in curvilinear paths to give beneficial load and stiffness distribution patterns. Buckling of composite panels is one area where fiber steering has been proven to be very effective. Fiber angles and predefined fiber angle variations are used in most of the research on fiber steered composites reported in the literature, however, from an optimization point of view it is attractive to design such variable stiffness (VS) structures in terms of lamination parameters (LPs). This results in a two-step design approach. In the first step a VS composite is designed in terms of LPs, and in the second step the LPs are converted into fiber angle distributions for each layer in the laminate. A methodology is proposed to convert a known LP distribution for a VS composite laminate into a realistic design in terms of fiber angles, with minimum loss of structural performance, whilst satisfying a constraint on in-plane fiber angle curvature. The proposed conversion process is formulated as an optimization problem and can be used for any number of equi-thickness plies. The methodology was tested by converting a known optimal LP design for a sample structure, a square plate under bi-axial compression into a fiber angle design. The effect of the in-plane curvature constraint, the number of layers in the laminate, and the choice of objective function for the conversion process were studied for a balanced symmetric lay-up. (C) 2011 Elsevier Ltd. All rights reserved.