Design

The field of fiber-reinforced plastics composites has undergone significant advancements, particularly in the design and simulation of thin-walled structures composed of plies with continuous unidirectional fibers or woven fabrics embedded in a polymer matrix. This article delves into the intricacies of the structural composite design process, offering insights into computer-aided design (CAD), computer-aided engineering (CAE), and computer-aided manufacturing (CAM) capabilities. 

CAD (Design phase)

The CAD design process serves as the initial phase, focusing on defining the overall geometry of the composite part and delineating zones of laminates with specific stacking sequences. This zone-based design approach, facilitated by CAD software, involves assigning laminates based on the total number of plies and their orientations, often conventional angles like 0°, 45°, 90°, and -45°. CAD not only lays the foundation for the structural design but also considers manufacturing constraints, allowing for accurate predictions of fiber orientations and ply deformation during draping.

CAE (Analysis phase)

After the initial phase of Computer-Aided Design (CAD), the process seamlessly progresses to Computer-Aided Engineering (CAE), where the structural integrity of the composite structure undergoes rigorous analysis under expected loads. A pivotal role is played by Finite Element Analysis (FEM), a widely adopted technique known for its efficacy, especially in handling complex geometries. Conversely, analytical methods, grounded in classical lamination and plate theories, offer expedited and precise solutions tailored to composite structures with simpler geometries.

Both FEM and analytical methods are strategically employed in CAE to validate and refine the design, ensuring the structural robustness of fiber-reinforced composite materials across various loading conditions. CAE meticulously evaluates the mechanical properties of the composite structure, taking into account factors such as stacking sequence, ply thickness, and orientation. Given the intricate nature of composite structures and the multitude of parameters influencing their behavior, CAE plays a crucial role in ensuring the validation and, when necessary, modification of the design initially provided by CAD.

This iterative interaction between CAD and CAE stands as an essential process in refining the design, ultimately aiming to achieve optimal stacking sequences for each region of the structure. 

CAM (Manufacturing phase)

Subsequently, the CAM phase bridges the virtual design to the physical manufacturing process. Specific CAM software simulates the ply deposition on a virtual machine, providing a practical representation of the manufacturing process. This step ensures that the designed stacking sequences are feasible and can be translated into numerical command programs for actual production. The integration of CAD, CAE, and CAM in the structural composite design process, signifies a holistic approach where design, analysis, and manufacturing seamlessly collaborate, contributing to the development of high-performance composite structures in industries demanding precision and reliability, such as aerospace.