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Composite materials have become popular in the application of aircraft structures.

The need for innovative designs has posed a great challenge. This tutorial discusses the optimization-driven design approach of a composite aircraft underbelly fairing using OptiStruct. The design takes a three-phased approach:
Phase 1 Concept design synthesis Free-size optimization is used to identify the optimal ply shapes and locations of patches per ply orientation. Design fine tuning Size optimization is used to identify the optimal thicknesses of each ply bundle. Ply stacking sequence optimization Shuffling optimization is used to obtain an optimal stacking sequence.

Phase 2 Phase 3

The process expands upon three important and advanced optimization techniques; free-size optimization, size optimization and ply stacking sequence optimization. By stringing these three techniques together, OptiStruct offers a unique and comprehensive process for the design and optimization of composite laminates. The process is automated and integrated in HyperWorks by generating the input data for a subsequent phase automatically from the previous design phase.

Problem definition
The finite element model of the underbelly fairing was generated in HyperMesh, as shown in the following image. Material properties for carbon-fiber were considered and represented using an orthotropic material (MAT8) for two dimensional elements. The fairing was modeled with four ply orientations (0, 90, 45 and -45) of uniform thickness. The SMEAR option is applied in the PCOMP card to eliminate stack biasing. Two load cases were defined to represent the operating conditions an internal uniform pressure loading of 0.02MPa and an external gravity loading of 6.75g. The fairing was considered to be riveted along its edges to the surrounding structure. Two equipment masses, weighing 2Kg and 3Kg each, were mounted to the fairing through RBE3 elements. The fairing has been designed considering two major performance criteria: the first natural frequency is at least 20Hz, and the maximum strain is less than 1000 micro-strain.

Motion studies are graphical simulations of motion for assembly models. You can incorporate visual properties such as lighting and camera perspective into a motion study. Motion studies do not change an assembly model or its properties. They simulate and animate the motion you prescribe for a model. You can use SolidWorks mates to restrict the motion of components in an assembly when you model motion. From a motion study, you can use MotionManager, a timeline-based interface that includes the following motion study tools: Animation (available in core SolidWorks) You can use Animation to animate the motion of assemblies.

Add motors to drive the motion of one or more parts of an assembly.

Prescribe the positions of assembly components at various times using set key points. Animation uses interpolation to define the motion of assembly components between key points.

Basic Motion (available in core SolidWorks) You can use Basic Motion for approximating the effects of motors, springs, contact, and gravity on assemblies. Basic Motion takes mass into account in calculating motion. Basic Motion computation is relatively fast, so you can use this for creating presentationworthy animations using physics-based simulations. Motion Analysis (available with the SolidWorks MotionTM add-in to SolidWorks Premium) You can use Motion Analysis for accurately simulating and analyzing the effects of motion elements (including forces, springs, dampers, and friction ) on an assembly. Motion Analysis uses computationally strong kinematic solvers, and accounts for material properties as well as mass and inertia in the computations. You can also use Motion Analysis to plot simulation results for further analysis. In addition, you can use the MotionManager toolbar to:

Change viewpoints. Display properties. Create distributable, presentation-worthy animations depicting the motion of an assembly.

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