Elaboration of Design and Optimization Methods for a Newly Developed CFRP Sandwich-like Structure Validated by Experimental Measurements and Finite Element Analysis

Nowadays, the application of composite materials and light-weight structures is required in those industrial applications where the primary design aims are weight saving, high stiffness, corrosion resistance and vibration damping. The first goal of the study was to construct a new light-weight structure that utilizes the advantageous characteristics of Carbon Fiber Reinforced Plastic (CFRP) and Aluminum (Al) materials; furthermore, the properties of sandwich structures and cellular plates. Thus, the newly constructed structure has CFRP face sheets and Al stiffeners, which was manufactured in order to take experimental measurements. The second aim of the research was the elaboration of calculation methods for the middle deflection of the investigated sandwich-like structure and the stresses that occurred in the structural elements. The calculation methods were elaborated; furthermore, validated by experimental measurements and Finite Element analysis. The third main goal was the elaboration of a mass and cost optimization method for the investigated structure applying the Flexible Tolerance optimization method. During the optimization, seven design constraints were considered: total deflection; buckling of face sheets; web buckling in stiffeners; stress in face sheets; stress in stiffeners; eigenfrequency of the structure and constraints for the design variables. The main added values of the research are the elaboration of the calculation methods relating to the middle deflection and the occurred stresses; furthermore, elaboration of the optimization method. The primary aim of the optimization was the construction of the most light-weighted structure because the new light-weight sandwich-like structure can be utilized in many industrial applications, e.g., elements of vehicles (ship floors, airplane base-plate); transport containers; building constructions (building floors, bridge decks).