Composite materials offer material properties as vectors rather than scalars, allowing a more efficient allocation of strength and stiffness through an orthogonal alignment of the internal fibre geometry. The current use of broad-goods not only fails to take advantage of this directionality, but also causes secondary failures which severely limit performance. A design methodology has been developed to produce viable composite components which do not suffer from unnecessary secondary stresses.

Sponsors/Collaborators

• EPSRC
• Messier-Dowty

Researchers

For some time, computer programs have been available which optimise the proportions of a given shape (by thickening or thinning) to achieve efficient proportions for a component. However, few programs can actually achieve the step of suggesting a good shape - an optimum configuration - in the first place. An efficient approach for doing this has now been demonstrated, following the process used in bone development, where an initially soft material, subject to a stress field, adds stiffening fibres in appropriate directions and removes unnecessary material.

Researchers

Within small three-dimensional components using composite materials, layers of unidirectional fibres cannot match the desired stress trajectories efficiently. A new design approach which yields optimised three-dimensional fibre layouts at a detailed level, and a matching fibre placement method to manufacture the designed shapes, are now being tested on aircraft landing gear components, in collaboration with Messier - Dowty Limited.

Sponsors / Collaborators

• Messier - Dowty
• EPSRC (IMI)

Researchers

Previous research within the manufacturing engineering group by Professor Colin Andrew gave BAe Airbus considerable understanding of the peen forming process used in shaping wing skins and has lead to significant process improvement. Current work on age forming is generating significant tooling improvement and will lead to further process development.

Sponsors / Collaborators

• BAe Airbus

Researcher