Session: 01-07-01: Nonlinear Problems in Aerospace Structures

Paper Number: 152303

152303 - Multi-Fidelity Models for Failure Onset Analysis of Composites Under Uncertainties 

The advancement of composite manufacturing technologies has enabled novel approaches to the design of high-performance composite structures. These innovations allow for improved stress distribution, increased stiffness, and enhanced overall structural performance. However, optimizing composite designs under uncertainty remains challenging, particularly when accounting for manufacturing defects and material variability [1].

This work proposes a multi-fidelity Gaussian Process Regression (GPR) framework for optimization under uncertainties in composite structures. The framework is designed to solve stress-constrained optimization problems, with the aim of minimizing both mass and strain energy, critical for achieving lightweight and efficient designs. It integrates low- and high-fidelity simulation models, leveraging the flexibility of the Carrera Unified Formulation (CUF) [2] to enhance the modeling of structural behavior. Low-fidelity simulations are based on Equivalent Single-Layer (ESL) models using through-the-thickness Taylor expansions, while high-fidelity simulations employ Layer-Wise (LW) models using Lagrange expansions, allowing for a detailed representation of the structural response at the layer level. CUF provides a computationally efficient and versatile framework that enables accurate predictions across different structural theories and captures the mechanical response of composite structures, even in the presence of manufacturing imperfections [3].

The multi-fidelity GPR approach balances computational costs with accuracy by combining the efficiency of low-fidelity ESL models for broad design exploration and the accuracy of high-fidelity LW models for capturing detailed local effects. This method is particularly suited for weight optimization in large-scale composite structures, providing robust designs that account for both material and load variability, as well as manufacturing-induced defects, ultimately leading to improved manufacturability and structural performance.

[1] A. Pagani, M. Petrolo, A. R. Sánchez-Majano. Stochastic characterization of multiscale material uncertainties on the fibre-matrix interface stress state of composite variable stiffness plates. International Journal of Engineering Science (2023).

[2] E. Carrera, M. Cinefra, M. Petrolo, E. Zappino. Finite Element Analysis of Structures through Unified Formulation. Wiley & Sons, Hoboken, New Jersey, USA. 2014.

[3] A. Pagani, A. R. Sánchez-Majano, D. Zamani, M. Petrolo, E. Carrera: Fundamental frequency layer-wise optimization of tow-steered composites considering gaps and overlaps. Aerotecnica Missili e Spazio (2024).

Presenting Author: Alfonso Pagani Politecnico di Torino

Presenting Author Biography: Alfonso Pagani is professor of aerospace structures at Politecnico di Torino's Department of Mechanical and Aerospace Engineering. He holds Ph.D. degrees in Aerospace Engineering from City University of London and in Fluid-dynamics (Aeroelasticity) from Politecnico di Torino. An active fellow of the Italian Association of Aeronautics and Astronautics (AIDAA), he is an associate editor for two journals and conducts research at MUL2 Lab, focusing on structures, space mechanisms, and advanced materials. He leads the ERC project PRE-ECO and is the deputy for Spoke 8 in the "Space It Up!" program. He has held visiting positions at Caltech, Purdue University, RMIT Melbourne, and Universidade do Porto.