Analysis of the deformation of conical shells made by 4D Printing of composites

4D printing of composites (4DPC) is a technique that allows the manufacturing of composite structures to shape without the use of a complex-shaped mold. Instead, only a flat mold is utilized. This innovative technique has been employed to make composite leaf springs with performance comparable to metallic springs, omega stiffeners, and corrugated core for flexible wings. Recently, this technique was applied to fabricate composite conical shells. While experimental work has successfully demonstrated the transformation from flat to conical shape, the development of a numerical method to replicate this transformation is highly desirable. The availability of such method not only provides theoretical support for the experimental result, it also provides means to develop other shapes. The lay-up sequence for transforming flat to conical shapes involves curvilinear fibers. Most if not all finite elements currently available deal only with straight fibers (even though the boundaries of the element may be curved). The objective of this research is to examine the efficiency of the analysis for the deformation of composite from flat to curve made by 4DPC by special finite elements containing curved fibers. The developed finite elements were used to determine the shapes of conical shells made using multiple distinct lay-up sequences. The direction of bending in curvilinear fiber structures is significantly influenced by the orientation of the fibers. This highlights the critical role of fiber orientation and layer composition in achieving desired shapes in 4D printed composites.