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Optimization of composite box-beam structures including effects of subcomponent interactions

Minimum mass designs are obtained for a simple box beam structure subject to bending, torque and combined bending/torque load cases. These designs are obtained subject to point strain and linear buckling constraints. The present work differs from previous efforts in that special attention is payed to including the effects of subcomponent panel interaction in the optimal design process. Two different approaches are used to impose the buckling constraints. When the global approach is used, buckling constraints are imposed on the global structure via a linear eigenvalue analysis. This approach allows the subcomponent panels to interact in a realistic manner. The results obtained using this approach are compared to results obtained using a traditional, less expensive approach, called the local approach. When the local approach is used, in-plane loads are extracted from the global model and used to impose buckling constraints on each subcomponent panel individually. In the global cases, it is found that there can be significant interaction between skin, spar, and rib design variables. This coupling is weak or nonexistent in the local designs. It is determined that weight savings of up to 7% may be obtained by using the global approach instead of the local approach to design these structures. Several of the designs obtained using the linear buckling analysis are subjected to a geometrically nonlinear analysis. For the designs which were subjected to bending loads, the innermost rib panel begins to collapse at less than half the intended design load and in a mode different from that predicted by linear analysis. The discrepancy between the predicted linear and nonlinear responses is attributed to the effects of the nonlinear rib crushing load, and the parameter which controls this rib collapse failure mode is shown to be the rib thickness. The rib collapse failure mode may be avoided by increasing the rib thickness above the value obtained from the (linear analysis based) optimizer. It is concluded that it would be necessary to include geometric nonlinearities in the design optimization process if the true optimum in this case were to be found.

Ragon, Scott A.

Effects of geometric nonlinearities on the response of optimized box beam structures

The present minimum-mass designs for a two-spar rectangular box beam were derived on the basis of linear-buckling FEM analysis constraints. In order to ascertain the effects of any geometric nonlinearities on these designs, each was subjected to a geometrically nonlinear FEM analysis. In all cases, the structure collapses below the design load, and does so in a mode which differs from that of linear theory. This discrepancy is attributable to such nonlinear panel-interaction mechanisms as rib-crusing loads. The optimized design is highly sensitive to crushing loads, relative to the nonoptimal design.

Ragon, S.

Design Optimization of Stiffened Panels with Postbuckling Constraints

The funding provided by the grant is used to complete the final stages of the development of a geometrically nonlinear analysis and design capability for the static response of compressively loaded prismatic plate structures. The analysis is based on the nonlinear finite strip method and is applicable for structures, such as stiffened panels or box columns, that can be modeled as assemblages of finite length plate strips. In an effort to reduce the computational cost of the nonlinear finite strip method, thus making it suitable for use in the design optimization environment, reduced basis techniques as described in various references by Noor are used in conjunction with the finite strip method. In addition, an efficient scheme for tracing the nonlinear equilibrium paths through highly nonlinear response curves was implemented. The new scheme, which is referred to as the normal flow algorithm, is based on homotopy methods, and is capable of negotiating highly nonlinear limit point instabilities with a reduced computational cost compared to the popular Ricks/Wempner and Chrisfield algorithms.

Guerdal, Zafer