Cost/weight optimization of composite prepreg structures for best draping strategy

The application of hand-laid carbon fiber prepreg is very expensive from a labor perspective Therefore the manufacturing cost should be included in the design process In this work. we propose a novel optimization framework which contains a draping simulation in combination with a detailed cost estimation package and the calculation of the structural performance based on FE We suggest applying the methodology in two steps First, a draping knowledge database is generated in which combinations of seed points and reference angles are evaluated in terms of fiber angle deviation. scrap, ultrasonic cuts and material shear Second, a cost/weight optimization framework picks the best sets of plies during the subsequent optimization The methodology is tested by means of a curved C-spar which is designed using plain weave anti unidirectional prepreg. Different objectives in the generation of the draping database lead to different design solutions (C) 2009 Elsevier Ltd All rights reserved