Numerical analysis of process-induced deformations and stresses in aeronautical composite components

Process-Induced Deformations (PIDs) pose notable challenges in fabricating composite aerostructures, particularly during the alignment phase of wing spars and skins in composite wing boxes. The present study explores the effects of design and geometric variables on PIDs and their consequent residual stresses within composite spars. The focus will be on components with C-shaped cross-sections, examining factors such as spring-in angles, deformations, and the distribution of 3D stresses throughout the thickness of these components. The research utilizes one dimensional, higher-order, layer-wise theories derived from the Carrera Unified Formulation (CUF) to overcome the traditionally time-consuming simulations for such large geometries. The cure-hardening instantaneously linear elastic (CHILE) model will be adopted for the numerical simulation. The present methodology facilitates a swift and effective assessment of residual stresses and PIDs, enabling prompt evaluation of various design options. This tool is particularly advantageous for exploring and optimizing designs of large and complex composite components and devising strategies to reduce the impact of PIDs.