Design optimization of laminated composite structures using explicit finite element analysis

Laminated composite materials are used in aerospace, civil and mechanical structural systems due to their superior material properties compared to the constituent materials as well as in comparison to traditional materials such as metals. Laminate structures are composed of multiple orthotropic material layers bonded together to form a single performing part. As such, the layup design of the material largely influences the structural performance. Optimization techniques such as the Genetic Algorithm (GA), Differential Evolution (DE), the Method of Feasible Directions (MFD), and others can be used to determine the optimal laminate composite material layup. In this thesis, sizing, shape and topology design optimization of laminated composites is carried out. Sizing optimization, such as the layer thickness, topology optimization, such as the layer orientation and material and the number of layers present, and shape optimization of the overall composite part contribute to the design optimization process of laminates. An optimization host program written in C++ has been developed to implement the optimization methodology of both population based and numerical gradient based methods. The performance of the composite structural system is evaluated through explicit finite element analysis of shell elements carried out using LS-DYNA. Results from numerical examples demonstrate that optimization design processes can significantly improve composite part performance through implementation of optimum material layup and part shape.