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Prediction of Manufacturing Induced Residual Stress and Deformation of Composites Using Mechanics of Structure Genome Based Shell Theory



An efficient shell model based on mechanics of structure genome is introduced to predict manufacturing induced residual stress and deformation for composite laminates. This model utilize shell elements in commercial finite element codes to represent the composite laminate, which greatly reduces the computational cost compared with a direct numerical simulation (DNS) using 3D solid elements or accuracy loss compared with using smeared properties. In this study, a line through the thickness of the composite laminate is chosen to be the structure genome, separating the original 3D body into a 1D through the thickness analysis and a 2D shell analysis. Constitutive relations for the shell elements, considering the effect of residual stress and strain, are constructed. The tool is modeled using 3D elements with a relative coarse mesh and a contact interaction is applied between the tool and composite part, as commonly done in a DNS. Several case studies are presented with comparison between DNS and analysis using smeared properties.

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