New Techniques for Composite Wing Manufacture

Abstract

This report addresses the construction of carbon fibre wing boxes and the problems as- sociated with using carbon fibre sheets rather than individual carbon fibre tapes. In the case that the wing boxes are developable surfaces the lay up of carbon fibre sheets is straightforward, since the fibres can follow the contours of the surface without any need for shearing or extension of the fibres. To further expand the potential design space for the wing boxes, this report investigates the lay up of sheets over non-developable surfaces where some shearing of the sheet is required to achieve the desired results. In this report, three analytical approaches are considered, driven by the results from numerical studies on different surface geometries. Each of the approaches offers insights as to the type of geometric perturbations achievable when constrained by a maximum shear angle.