Thickness optimization of composite plates by Box’s complex method considering the process and material parameters in compression molding of SMC

The main goal of this study is to optimize the structural thickness distribution for improving the mechanical performance of composite structures manufactured by compression molding processes. During the preliminary preparation for optimization, a processing simulation program was developed to predict the fiber volume fraction and orientation using a Control Volume/Finite Element method. To verify the effects of the processing conditions on the mechanical properties, a few simple geometries and loading conditions were investigated. Considering the fiber state changes, the optimal thickness distributions of a plate in one- and two-dimension have been searched. Box’s complex method was applied to solve the non-linear inequality constrained problem.