Optimisation of process-induced residual stresses in composite laminates by different genetic algorithm and finite element simulation coupling methods

TY – JOUR

T1 – Optimisation of process-induced residual stresses in composite laminates by different genetic algorithm and finite element simulation coupling methods

AU – Ma, Hong

AU – Pierce, Robert S.

AU – Beauson, Justine

PY – 2024

Y1 – 2024

N2 – To address the residual stress induced during the cure of fibre reinforced thermoset polymer composites, two different approaches were suggested for coupling a non-dominated sorting genetic algorithm (NSGA-II) with finite element (FE) simulations based on a viscoelastic constitutive law. These two approaches were proposed with consideration of different ways of integrating NSGA-II and the FE model. In Approach A, NSGA-II was performed based on results from a series of simulations under various combinations of cure variables. Alternatively, Approach B employed NSGA-II to iteratively update and optimise the cure profile for subsequent simulations. Results indicated that both approaches achieved simultaneous reductions in cure time and macroscale residual stress, with Approach B showing further improvements due to the direct coupling between the NSGA-II and simulations. Specifically, the maximum residual stress and cure time optimised by Approach A were reduced by 59250 while those obtained by Approach B were reduced by 710249 compared to those based on the manufacturer recommended cure profile. The evolution of stress in composites based on optimised cure profiles from these two approaches was also elucidated. Additionally, microscale modelling further revealed a 35RVE) model was also shown, depending upon the approach adopted. Ultimately, by combining a NSGA-II and FE simulations, the optimisation of cure time and residual stress at the macroscale and cure time together with a reduction of microscale stress could be realised.

AB – To address the residual stress induced during the cure of fibre reinforced thermoset polymer composites, two different approaches were suggested for coupling a non-dominated sorting genetic algorithm (NSGA-II) with finite element (FE) simulations based on a viscoelastic constitutive law. These two approaches were proposed with consideration of different ways of integrating NSGA-II and the FE model. In Approach A, NSGA-II was performed based on results from a series of simulations under various combinations of cure variables. Alternatively, Approach B employed NSGA-II to iteratively update and optimise the cure profile for subsequent simulations. Results indicated that both approaches achieved simultaneous reductions in cure time and macroscale residual stress, with Approach B showing further improvements due to the direct coupling between the NSGA-II and simulations. Specifically, the maximum residual stress and cure time optimised by Approach A were reduced by 59250 while those obtained by Approach B were reduced by 710249 compared to those based on the manufacturer recommended cure profile. The evolution of stress in composites based on optimised cure profiles from these two approaches was also elucidated. Additionally, microscale modelling further revealed a 35RVE) model was also shown, depending upon the approach adopted. Ultimately, by combining a NSGA-II and FE simulations, the optimisation of cure time and residual stress at the macroscale and cure time together with a reduction of microscale stress could be realised.

KW – Polymer-matrix composites

KW – Residual/internal stress

KW – Computational modelling

KW – Cure

U2 – 10.1177/00219983241268895

DO – 10.1177/00219983241268895

M3 – Journal article

SN – 0021-9983

JO – Journal of Composite Materials

JF – Journal of Composite Materials

M1 – 00219983241268895

ER –