COMPLAS 2025

A Concurrent Workflow for the Topology Optimisation of Fibre Reinforced Composite Components of Increased Strength

  • Pissas, George (National Technical University of Athens)
  • Triantafyllou, Savvas (National Technical University of Athens)

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Additive manufacturing has revolutionized the production of complex geometries, enabling the fabrication of lightweight, high-performance structures with tailored properties. Fibre-reinforced composites (FRCs) stand out for their exceptional strength-to-weight ratio, durability, and adaptability to various engineering applications. However, the complexity of processing these materials arises from factors such as fibre-matrix interactions, anisotropic behavior, and the need for precise control over fibre orientation to achieve optimal mechanical performance. To address these challenges, topology optimization techniques incorporating fibre-orientation have emerged, allowing for the design of structures that maximize stiffness and strength while minimizing weight. Furthermore, understanding and predicting damage evolution in these composites is crucial for ensuring structural integrity. The phase-field method has gained prominence as a powerful computational approach for damage modeling in FRCs, providing insights into crack initiation, propagation, branching and coalescence. In this work, a unified framework for producing and simulating material domains with optimized topologies and fibre layouts is presented. The approach integrates topology optimization and fibre orientation optimization to design high-performance structures that maximize stiffness and strength. To this end, a Virtual Element Method (VEM) based SIMP method is employed. Furthermore, to resolve intra-laminar damage in fibre-reinforced optimized layouts, an anisotropic cohesive phase field model is used. The cohesive model incorporates a linear crack-surface density functional and a quasi-quadratic degradation function custom fit to model the quasi-brittle response of FRCs. The overarching aim is to enhance not only the mechanical performance but also the fracture resistance of the optimized domains, ensuring the development of damage-resistant specimens for advanced engineering applications.