Generating the Best Stacking Sequence Table for the Design of Blended Composite Structures

In order to improve the ability of a large-scale light-weight composite structure to carry tensile or compressive loads, stiffeners are added to the structure. The stiffeners divide the structure into several smaller panels. For a composite structure to be manufacturable, it is necessary that plies are continuous in multiple adjacent panels. To be able to prescribe a manufacturable design, an optimization algorithm can be coupled with a reference table for the stacking sequences (SST). As long as the ply stacks are selected from the SST, it is guaranteed that the design is manufacturable and all strength related guidelines associated with the design of composite structures are satisfied. An SST is made only based on strength related guidelines. Therefore, there exist a large number of possibilities for SSTs. Minimized mass is a typical goal in the design of aircraft structures. Different SSTs result in different values for the minimized mass. Thus it is crucial to perform optimization based on the SST which results in the lowest mass. This paper aims to introduce an approach to generate a unique SST resulting in the lowest mass. The proposed method is applied to the optimization problem of a stiffened composite structure resembling the skin of an aircraft wing box.