Tool-part interaction during the manufacture of the bistable composite shells with initial curvature is inevitable, which has a noticeable influence on stable configurations. The effect of tool-part interaction is considered by introducing a shear layer whose parameters are determined by a series of experiments. This paper develops an analytical model with shear layer effect based on the Rayleigh-Ritz model to capture the configuration variation with bistable composite shell with initial curvature. The model reveals the rule of curvature change in different radii and plies, which provides a criterion for the existence of bistability. The results show tool-part interaction has a significant influence on thin bistable composite shells with initial curvature whose prediction accuracy is improved. The analytical predictions are verified by results based on the experiments and finite element models. Moreover, the influences of initial radius, cross-section angle, stacking sequence, and twisting response are analyzed. The twist behavior of two stable configurations is investigated, which can provide a guide for designing the bistable composite structures.
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