Multi-objective CoFRP patch optimization with consideration of manufacturing constraints and integrated warpage simulation

Abstract The combination of continuous and discontinuous fiber reinforced plastics in CoDiCoFRP structures offer a wide range of possible applications, which require specific optimization strategies. Thereby, the consideration of manufacturing constraints during the optimization increases the quality of the results significantly. In this work, a multi-objective optimization workflow for unidirectional continuous fiber reinforcement patches is proposed, in which a kinematic draping simulation of the CoFRP material and a warpage simulation of the CoDiCoFRP structure are integrated. An evolutionary algorithm is applied to solve the multi-objective patch optimization problem. The optimization objectives are, on the one hand, distortion and residual stresses as functions of the manufacturing process. On the other hand, the overall strain energy is used as objective function of a structural load case. The performance of the proposed algorithm is demonstrated using the example of a double-curved CoDiCoFRP reference structure.