Sublaminate library generation for optimization of multi-panel composite parts

A non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method of creating a library of sublaminates used in optimizing fiber orientations of a multi-layer composite part subdivided into panels that each comprise a fraction of the area of the composite part, the method comprising:

• creating an integer tree of sublaminates that each comprise consecutively stacked layers having a unique sequence of fiber orientations;
• checking the sublaminates, based on the fiber orientations of the consecutively stacked layers of the sublaminates, for compliance with stacking sequence rules that constrain how fiber orientations are sequenced;
• pruning branches from the integer tree by removing sublaminates that do not comply with the stacking sequence rules;
• generating new sublaminates that each include an additional layer, by, for each of multiple fiber orientations:
• selecting a sublaminate that was not removed;
• and
• creating a new branch within the integer tree by generating a new sublaminate by appending a layer having the fiber orientation to the selected sublaminate;
• repeating the checking, the removing, and the generating at the integer tree until a maximum number of layers has been reached;
• and
• storing the sublaminates in memory as a library of available sublaminates for designing the composite part.

An apparatus comprising:

• a memory that stores stacking sequence rules that constrain how fiber orientations are permitted to be sequenced within a multi-layer composite part subdivided into panels that each comprise a fraction of the area of the composite part;
• and
• a controller that creates a library of sublaminates used in optimizing fiber orientations of the composite part, by:
• creating an integer tree of sublaminates that each comprise consecutively stacked layers having a unique sequence of fiber orientations, checking the sublaminates for compliance with the stacking sequence rules based on the fiber orientations of the consecutively stacked layers of the sublaminates;
• and pruning branches from the integer tree by removing sublaminates that do not comply with the stacking sequence rules,
• the controller generates new sublaminates that each include an additional layer, by, for each of multiple fiber orientations:
• selecting a sublaminate that was not removed, and creating a new branch within the integer tree by generating a new sublaminate by appending a layer having the fiber orientation to the selected sublaminate, and
• the controller repeats the checking, the removing, and the generating at the integer tree until a maximum number of layers has been reached, and stores the sublaminates in the memory as a library of available sublaminates for designing the composite part.