A virtual manufacturing tool for the prediction of process-induced deformation in thin composite structures

The paper presents a virtual framework for the analysis of process-induced deformations in composite thin structures. The numerical model is based on a refined one-dimensional structural theory developed by means of the Carrera unified formulation. A cure hardening instantaneously linear elastic constitutive model has been used to describe the evolution of the curing process. An iterative solution has been implemented to simulate the full manufacturing process. Curved thin composite structures have been considered in different numerical examples. The impact of the geometrical parameters as well as the impact of the laminate stacking sequences has been considered. The results have shown that the manufacturing process may introduce large deformations that may affect the stiffness and stability performance of thin composite structures. The present tool has been demonstrated to be able to predict with accuracy process-induced deformations.