DESIGN AND COMPUTATIONAL VALIDATION METHODS OF A COMPOSITE PASSENGER AIRCRAFT SEAT WITH ADVANCED MATERIAL MODELING TECHNIQUE
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As industry has adopted the use of carbon fiber reinforced plastics (CFRPs) at an increasing rate, the need for specially developed design and analysis methods increase likewise. Specifically, through development of new low-cost CFRP materials, a broadening range of industries are intent on adopting the benefits of CFRPs at attainable costs. With the invention of new composite materials and material configurations, arises the need for new modeling techniques and practices to give users more capabilities in the design process. This thesis is presented to provide further insight into computational design processes and validation methods associated with a newly developed CFRP material. A laminate optimization process for CFRPs is compared with traditional topology optimization (TO) processes as conceptual design tools for a passenger aircraft seat concept, showing potential of 8% performance gain over traditional materials and methods. Additional work is presented into the development of an advanced material modeling technique specifically tuned and correlated for a new CFRP material system, denoted as long fiber prepreg sheet (LFPS). This LFPS modeling technique has been developed within LS-DYNA software to have the capability to model the progression of intralaminar and interlaminar failure. This technique has been correlated to experimental results through explicit dynamic analysis of three experimental testing procedures, producing maximum load results within 1%, 10%, and 2% of each tensile, short-beam, and shear scenarios, respectively. The LFPS modeling technique also showed matching failure mechanisms to each testing scenario. This modeling technique has been developed with the intent to give future users the capability to model LFPS structures with confidence and to provide insight for other users to develop material modeling techniques for similar materials. Further work has been presented which begins to evaluate the efficacy and performance of the developed LFPS modeling technique on large-scale practical problems. The culmination of the work presented in this thesis leaves a strong foundation of design and validation methods for improving capabilities in modeling the LFPS material and can act as a framework for other techniques to be developed for similar materials.