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High load carrying structures made from folded composite materials

机译:由折叠复合材料制成的高负荷承载结构

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摘要

Large design and manufacturing effort for high load carrying composite structures results from anisotropic material behavior, tedious curing or forming conditions as well as high sensitivity to manufacturing defects. Such challenges limit the design freedom and result in large cost and time effort. A novel design approach is proposed to realize load carrying structures based on the utilization of the outstanding flexibility of thin composite shells and the "complexity for free" approach of additive manufacturing. To this purpose, highly integrated structures are created by folding cured and thin composite shells around additively manufactured internal core topologies. The developed structures do not require complex molding approaches, while maintaining a high degree of manufacturing quality. A multidisciplinary design optimization is used to fully exploit the design freedom and the load carrying capabilities of the structure. Following the design concept, a UAV wing structure that carries more than 100 times its own weight is developed, optimized and tested to validate the design approach and demonstrate load carrying ability and manufacturing quality.
机译:高载荷复合结构的大型设计和制造努力由各向异性材料行为,繁琐的固化或形成条件以及对制造缺陷的高敏感性。此类挑战限制了设计自由并导致大量成本和时间努力。提出了一种新颖的设计方法,实现了基于利用薄复合壳的突出灵活性的载荷载体结构和添加剂制造的“自由”方法的“复杂性”。为此目的,通过折叠固化和薄的复合壳体,周围的内核拓扑结构折叠固化和薄复合壳产生高度集成的结构。开发的结构不需要复杂的模塑方法,同时保持高度的制造质量。多学科设计优化用于充分利用设计自由和结构的负载承载能力。在设计理念之后,开发,优化和测试了一个拥有超过100倍的UAV翼结构,以验证设计方法,并展示负载承载能力和制造质量。

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