Design and optimization of composite parts using numerical simulations

The article deals with the use of numerical simulations for the design and optimization of parts with complicated shapes made from composite materials. An airbox designed for a light single-seat racing car was chosen as a representative example. The numerical analysis is primarily focused on the maximum reduction of the mass of the component while retaining adequate stiffness and strength and also taking into account the manufacturing technology of the component. Carbon composite fabrics in combination with high performance epoxy resin were used to ensure the maximum stiifness of the part. In order to ünd the best option, an advanced CAE simulation based on the Finite Element Method was used with a special module designated directly for creating models from alternative materials. Zone-based and ply-based FE models were created to find the optimal layout of the individual plies of the laminate. Maximum stress failure criterion was used to evaluate the strength of the part. A 3D model for the numerical simulation follows all the layers of the composite materials, including cuts, notches, resin drops and precise calculation of the main directions of the fibres and their distortion or overlap caused by more complex shaped surfaces.