From stacking sequences to ply layouts: An algorithm to design manufacturable composite structures

The problem of computing the ply lay-outs of a composite structure from the definition of the stacking sequences of the zones is studied in this paper. These stacking sequences result from the design of the composite structure and they are considered to be admissible with respect to standard composite design and manufacturing rules. This paper shows that the definition of blended stacking sequences does not necessarily lead to a possible solution for the ply layouts. Therefore, the design process of a composite structure must include a further step after computing the stacking sequences which is to compute the ply layouts. The paper presents an algorithm to compute a ply layout solution for a given set of stacking sequences. Using a backtracking approach, it efficiently checks all the possible ply layout combinations to find a solution. Some numerical experiments are presented to study the mapping between stacking sequences and ply layouts and the existence of a ply layout solution.