Aerostructural Efficiency of Damage Tolerant Composites via Optimised Fibre Placement
Lead Research Organisation:
University of Bristol
Department Name: Aerospace Engineering
Abstract
The proposed project will create new capability to improve the structural efficiency of laminated carbon fibre composites. It will reduce weight and production cost by at least 10% (and possibly up to 30%) compared with existing stiffened panels made from pre-impregnated material. The new methods will facilitate the development of game-changing technology. The key innovation of the project will be to exploit state-of-the-art manufacturing, Variable Angle Tow (VAT) placement (where stiff carbon fibres are steered along curves to maximize structural performance). Ongoing studies suggest that such savings are achievable for standard test specimens (coupons) but new understanding is required to fully characterise structural and material behaviour from the full component level down to individual lamina and their interfaces. The entire structural system including material, geometrical and manufacturing parameters will be optimised. The extra design freedoms, created by curved fibre trajectories, provide scope for pushing back the envelope of structural efficiency. The academic team provide a unique capability to fulfil this vision. They have a proven track record in manufacture, modelling and design of composite materials and structures and have clear routes to exploitation via a pivotal industrial base. Their novel damage tolerance modelling techniques indicate that large improvements in material efficiency can be achieved if critical positions of delamination damage are tailored via through-thickness laminate optimisation. The team's preliminary VAT results indicate the prospect of developing buckle-free structures, reducing the need for stiffeners, with associated substantial cost and weight savings. Moreover, the specific manufacturing capability to produce variable angle fibres is unique to the UK, having been modified from an embroidery machine, using dry fibres rather than pre-impregnated material. Airbus and GKN will support the project with 290k of direct funding.
Publications

Coburn B
(2016)
Buckling analysis, design and optimisation of variable-stiffness sandwich panels
in International Journal of Solids and Structures

Coburn B
(2014)
Buckling analysis of stiffened variable angle tow panels
in Composite Structures

Dang T
(2013)
A numerical study on impact and compression after impact behaviour of variable angle tow laminates
in Composite Structures

Groh R
(2013)
A 2D equivalent single-layer formulation for the effect of transverse shear on laminated plates with curvilinear fibres
in Composite Structures

Groh R
(2014)
Buckling analysis of variable angle tow, variable thickness panels with transverse shear effects
in Composite Structures

Groh R
(2016)
A computationally efficient 2D model for inherently equilibrated 3D stress predictions in heterogeneous laminated plates. Part II: Model validation
in Composite Structures

Groh R
(2016)
A computationally efficient 2D model for inherently equilibrated 3D stress predictions in heterogeneous laminated plates. Part I: Model formulation
in Composite Structures


Kim B
(2015)
Computer aided modelling of variable angle tow composites manufactured by continuous tow shearing
in Composite Structures

Kim B
(2014)
Manufacturing characteristics of the continuous tow shearing method for manufacturing of variable angle tow composites
in Composites Part A: Applied Science and Manufacturing
Description | Developed and patented applied for new manufacturing process of composite materials , Continuous Tow Shearing. Methods we developed for stress analysis are being adopted by various researchers as shown by the high number of citations for our papers |
Exploitation Route | EPSRC Cimcomp grant for Eric KIm (PDRA on this grant) ATI VIEWS grant led by GKN spinout-ICOMAT H2020 MCS ITN FULLCOMP |
Sectors | Aerospace, Defence and Marine |
Description | The analysis methods were adopted by Airbus and passed a technology gate level 1 review in 2013. ICOMAT spinout from University in 2019 |
First Year Of Impact | 2013 |
Sector | Aerospace, Defence and Marine |
Impact Types | Economic |
Description | Industrial CASE award |
Amount | £100,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Academic/University |
Country | United Kingdom |
Start | 01/2014 |
End | 12/2018 |
Description | VIEWS programme |
Amount | £100,000 (GBP) |
Organisation | Aerospace Technology Institute |
Sector | Private |
Country | United Kingdom |
Start | 03/2014 |
End | 02/2016 |
Description | centre for doctoral training |
Amount | £240,000 (GBP) |
Funding ID | two studentships under CDT |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Academic/University |
Country | United Kingdom |
Start |
Title | buckling and postbuckling methods |
Description | Software |
Type Of Material | Technology assay or reagent |
Year Produced | 2012 |
Provided To Others? | Yes |
Impact | Software delivered to Airbus on buckling and postbucking of variable stiffness panels |
Description | Airbus tow steering |
Organisation | Airbus Group |
Department | Airbus Operations |
Country | United Kingdom |
Sector | Private |
PI Contribution | Quarterly technical meetings/presentations. Conference and journal papers |
Collaborator Contribution | Airbus provided feedback on our progress and also gave us case studies to work with |
Impact | See publication list for EPSRC grant EP/H026371/1 |
Start Year | 2010 |
Description | GKN tow steering |
Organisation | GKN |
Department | GKN Aerospace |
Country | United Kingdom |
Sector | Private |
PI Contribution | Technical presentations/discusssions |
Collaborator Contribution | Advice on progress and case studies |
Impact | See publication list for EPSRC grant EP/H026371/1 |
Start Year | 2010 |
Description | NASA |
Organisation | National Aeronautics and Space Administration (NASA) |
Department | NASA Langley Research Centre |
Country | United States |
Sector | Public |
PI Contribution | Buckling of plates and shells methods. |
Collaborator Contribution | Hosted visits from 2001 inwards |
Impact | Journal papers with Nemeth 2007, 2009 |
Title | Tow placement apparatus and method |
Description | New Composite materials manufacturing technique. |
IP Reference | GB2492594 |
Protection | Patent application published |
Year Protection Granted | 2013 |
Licensed | No |
Impact | Further investment by GKN and Airbus. CIMcomp fellowship for Kim and lectureship for Kim at University of Bristol |
Title | Buckling and Postbuckling models |
Description | Matlab codes to Airbus |
Type Of Technology | Software |
Year Produced | 2012 |
Impact | Successively passed Technology Gate review with Airbus |
Company Name | ICOMAT LIMITED |
Description | We developed a new composites manufacturing procedure, called continuous tow shearing. We also patented this. The work was further developed by postdoc (Kim), whi is now alecturer at Bristol and Zympeloudis (ACCIS CDT PhD student). The latter is now Chief executive, after having completed his PhD |
Year Established | 2019 |
Impact | too early |