M. Tech. Mechanical Engineering. / Shows Drape simulation software tool to simulate a digital standard for real life production of contour sensitive parts with CFRC materials in the aerospace and manufacturing industries.

A continuous physical cake made up of porous fibrous media can be formed by using air to draw the fibers to a moving screen. A numerical model of the formation of this cake has been formulated and solved. The numerical model is based on solving Darcy’s law, the Bernoulli equation, and two-material related experimental correlations at discrete points along the screen. A permeability measurement test apparatus was designed and built, and experiments were run to determine the experimental relations for two different materials. A computer code was then written to solve the system of equations at each point on the screen and give a density distribution of the resulting cake. Tests were then run to see the effects of various density anomalies in the material at different points along the screen. The results of the experiments show that the first material was more permeable and more compressible than the second material. This lead to distinct differences in the cake that the two formed in the numerical model. The first material formed a fairly constant density cake that was not greatly affected by the density anomalies. The second material had a large variation in density across the final cake height and was affected more by the different density anomalies. / Master of Science

A dissertation submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the degree of Master of Science in Engineering. Johannesburg, October 2017 / This research looks into the manufacturing process of complex geometries using continuous fibre reinforced thermoplastics (CFRTP). The purpose of this work was to develop methods that will enable the production of defect free complex components. This was achieved by investigating the key process parameters in the CFRTP manufacturing process, and optimizing them in order to improve the quality of components. The investi- gations were performed with the aid of software making use of the finite element method, and this was found to be instrumental in predicting the formability of geometries. The re- search showed that the formability of complex geometry is largely determined by the ability of the laminate to be draped into the required geometry. The forming mechanisms that take place during the draping process can be linked to the formation of defects where draping is unsuccessful. The study also showed that the quality of the drape can be influenced by blank and tool design factors. It was also shown that the blank can be manipulated using a restraint mechanism to improve the formability of geometries. The effect of processing parameters such as forming speed, forming pressure and tool temperature were also investigated. The research resulted in the formulation of guidelines to follow when manufacturing CFRTP components. The developments that were made were successfully implemented to improve the formability of a complex component that had previously been difficult to form without defects. / MT2018

The design of composite laminated panels is a combinatorial problem when the orientation of the fibers in each layer is restricted to a discrete pool of angles. Additionally, composite laminates often have many optimal and near-optimal designs, and the designer may benefit by knowing many of those designs. Genetic algorithms are well suited for laminate design because they can handle the combinatorial nature of the problem and they permit the designer to obtain many near-optimal designs. However, their computational cost is high for most structural optimization problems. This work describes several attempts to reduce the cost of optimizing composite laminates using genetic algorithms. First, the use of a genetic algorithm to maximize the buckling load of a fixed thickness composite laminate is studied. Various genetic parameters, including population size, probability of mutation, and probability of crossover are optimized by numerical experiments. A new genetic operator - stack swap - is proposed and shown to be effective in reducing the cost of the optimization. Second, the genetic algorithm is revised and improved for minimum thickness design of composite laminated plates. The influence on the genetic search of the penalty functions enforcing failure constraints is studied. Combining fixed and proportional penalty functions is found to be the most efficient strategy. Improved selection, mutation, and stack swap operators are proposed. The use of an operator called scaling mutation that projects designs towards the feasible domain is investigated. The improvements in the genetic algorithm are shown to reduce the average price of the search by more than 50%. Next, the improved genetic algorithm for minimum thickness laminate design is applied to a more complex wing box-beam optimization problem. Tuning the genetic algorithm on this problem shows that, because the maximum length of a search is limited, the optimal population size does not grow with the size of the design space. If the probability of applying stack swap is reduced with the number of independent laminates in the wing box, stack swap enhances the performance of the genetic search on the wing box -beam problem. Finally, the possibility of running many searches is investigated. It is empirically shown that several short searches can be more efficient than a long one, especially when high levels of reliability are required. An example is given where a genetic algorithm is specifically modified for better efficiency in the context of repeated short runs. A procedure is studied that enables predicting reliability at later stages of the search. / Ph. D.