COMPOSITES 2025

Finite element analysis (FEA) of bio-inspired helicoid carbon fibre-reinforced polymers (CFRPs) under open-hole tension and compression

  • Wang, Hongyan (Imperial College London)
  • Kazemi, Erfan (Imperial College London)
  • Mencattelli, Lorenzo (Imperial College London/ Helicoid Industries)
  • Walsh, Oran (Spirit AeroSystems Belfast)
  • Pinho, Silvestre (Imperial College London)

In session: CT - Structures

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Modern aircraft design has an increasing demand for lightweight, high-strength, high damage-resistant structural materials, with carbon fibre-reinforced polymers (CFRPs) showing promising potential. However, during flight, complex loading conditions in CFRP components could potentially lead to the failure of components. One approach to address this issue and enhance structural efficiency is the optimisation of the microstructure of the components. Of many existing CFRP microstructural design strategies, the bio-inspired helicoid design has demonstrated enhanced performance compared to conventional-designed CFRPs [1]. Bio-inspired helicoid microstructures mimic the helicoidal architecture of the mantis shrimp's dactyl club periodic region, which can significantly improve energy dissipation, damage tolerance, and load-bearing capability in the structure [2, 3]. Figure 1 shows the microstructures of conventional CFRPs (on the left) the bio-inspired helicoid CFRPs (on the right). As shown in Figure 1, conventional CFRPs, such as quasi-isotropic (QI) and hard-layup configurations, utilise the 0°, 90°, and ±45° plies. In contrast, helicoid CFRPs have more discrete ply angles, which can be designed to have either constant or non-uniform pitch angles [5]. This design flexibility of helicoid CFRPs enables an infinite number of possibilities, and thus it would be a labour-intensive process to manufacture the respective designs and examine their mechanical properties. As a result, to better understand the response of helicoid CFRPs for large aircraft structural components, we employed finite element analysis (FEA) to predict the mechanical properties of CFRPs and identify the most suitable layups. We aim to develop a high-performance FEA framework for accurate property prediction of helicoid CFRPs with various layups, under different loading conditions. We evaluated the mechanical properties and damage progress of the selected helicoid CFRPs under open hole tension (OHT) and open hole compression (OHC) tests, using the FEA method. After that, we selected suitable helicoid layups to be eventually used for large components. Kazemi et al. [6] evaluated the feasibility of manufacturing and compared the performance of the manufactured laminates with that of the conventional baseline counterpart.