Advanced optimal design concepts for composite material aircraft repair

The application of an automated optimization approach for bonded composite patch design is investigated. To do so, a finite element computer analysis tool to evaluate patch design quality was developed. This tool examines both the mechanical and the thermal issues of the problem. The optimized shape is obtained with a bi-quadratic B-spline surface that represents the top surface of the patch. Additional design variables corresponding to the ply angles are also used. Furthermore, a multi-objective optimization approach was developed to treat multiple and uncertain loads. This formulation aims at designing according to the most unfavorable mechanical and thermal loads.; The problem of finding the optimal patch shape for several situations is addressed. The objective is to minimize a stress component at a specific point in the host structure (plate) while ensuring acceptable stress levels in the adhesive. A parametric study is performed in order to identify the effects of various shape parameters on the quality of the repair and its optimal configuration. The effects of mechanical loads and service temperature are also investigated. Two bonding methods are considered, as they imply different thermal histories.; It is shown that the proposed techniques are effective and inexpensive for analyzing and optimizing composite patch repairs. It is also shown that thermal effects should not only be present in the analysis, but that they play a paramount role on the resulting quality of the optimized design. In all cases, the optimized configuration results in a significant reduction of the desired stress level by deflecting the loads away from rather than over the damage zone, as is the case with standard designs. Furthermore, the automated optimization ensures the safety of the patch design for all considered operating conditions.