METHOD FOR MAKING PRESTRESSED SHELLS HAVING TUNABLE BISTABILITY

Abstract

In a method for manufacturing prestressed shells having tunable bistability, in order to determine the appropriate prestress to be applied to the bistable structure/shell, it provides: clamping a shell by applying a predetermined curvature on a portion of its edge; defining a discrete shell model dependent on a small number of configuration parameters q_i, (i<5), by projecting the non-linear shell model of Marguerre-von Kármán onto an appropriate finite dimensional space so that the projection does not significantly alter the strain elastic energy; tracing the stability maps in the space of the design parameters by minimizing the discrete representation of the strain elastic energy E(q_i;p_i) thus obtained; and choosing the design parameters providing the prestress needed to obtain the desired response in terms of project requirements.

Claims

1. A design method for manufacturing prestressed shells having tuned bistability, wherein, to determine the appropriate prestress to be applied to the bistable structure/shell, the method envisages the following operating steps: A). clamping a shell by applying a predetermined curvature on a portion of its edge: the prestress which is obtained by imposing the clamp depends on a finite number of design parameters p.sub.i={h.sub.i=1, 2 . . . ; m.sub.i=1, 2 . . . ; c}: h.sub.i, m.sub.i are the parameters representative of the shape of the initial stress-free configuration of the shell, i.e. free from external constraints, and of the material while c is the curvature of the clamp; B). defining a discrete shell model dependent on a small number of configuration parameters q.sub.i, (i<5) by projecting the non-linear shell model of Marguerre-von Kármán onto an appropriate finite dimensional space; the projection does not significantly alter the elastic energy; C). tracing the stability maps in the space of the design parameters by means of the discrete representation of the elastic energy E(q.sub.i;p.sub.i) thus obtained; this allows to determine the number and the shape of the stable equilibrium configurations of the clamped shell, which at each load level correspond to a particular choice of the design parameters; D). choosing the design parameters providing the necessary prestress to obtain the desired behaviour in terms of project requirements; whereby obtaining: designing the shapes that the shell must assume during the loading process according to the performance requirements; establishing the critical load levels at which the transition must occur, choosing a point whose corresponding clamped shell has only one stable configuration for F=0, two for F.sub.2≤F≤F.sub.1 and again one for F>F.sub.1; changing the critical transition loads also during the operation of the structure, to fulfill possible changes in the performance requirements; identifying the corresponding optimized shape of the shell when free from constraints.

2. A method according to claim 1, wherein, as regards step A), shells whose natural stress-free configuration has average surface given by the function: $w_0=\frac{x_2^2}{2}\left[h_0+\left(h_f-h_0\right)\frac{x_1}{L_1}\right]$ wherein the design parameters representative of the shape of the shell are in this case: h.sub.0, which is the curvature of the edge x.sub.1=0 which will be clamped to induce the prestress; h.sub.f, which is the curvature of the opposite edge, which remains free; L.sub.2/L.sub.1, the planform aspect ratio.

3. A method according to claim 1, wherein, as regards step A), for composite shells the design parameters representative of the material are the characteristics of the elementary ply and the lamination sequence.

4. A method according to claim 3, wherein by choosing an eight-layer antisymmetric laminate of the [α/−α/−α/α/−α/α/α/−α] type, the design parameters are: E.sub.1,E.sub.2,G.sub.12,v.sub.12, which are the properties of the elementary ply; t.sub.l, which is the thickness of the elementary ply; α, which is the lamination angle; thus obtaining that the prestress in the shell is a function of the choice of ten design parameters p={h.sub.0,h.sub.1, L.sub.2/L.sub.1; E.sub.1,E.sub.2,G.sub.12,v.sub.12,t.sub.1, α; c} the last of which, i.e. the curvature of the clamp c to be assigned to the side x.sub.1=0, can be modified during operation.

5. A method according to claim 1, wherein, as regards step B), to obtain a discrete approximation of the elastic energy of the shell, comprising the membrane and bending contributions, a polynomial form can be chosen to describe the curvature of the shell in the generic configuration; in this case the configuration parameters being the coefficients q={q.sub.1, q.sub.2, . . . , q.sub.n} of the polynomials describing the curvature of the shell and that, together with the design parameters, define the elastic energy thereof.

6. A method according to claim 1, wherein, as regards step C), setting the material parameters relating to: characteristics of the elementary ply, lamination sequence, aspect ratio, curvature of the clamping, it is possible to minimize the polynomial approximation of the elastic energy with respect to the configuration parameters and to determine, for each possible choice of curvatures h.sub.0,h.sub.f of the edges x.sub.1=0, L.sub.x of the free shell and for each load level, the number, the shape, the elastic energy etc., of the stable equilibrium configurations that the shell exhibits after clamping its x.sub.1=0 edge, i.e. the design objectives.

7. A method according to claim 6, wherein, the information concerning the stable equilibrium configurations that the shell exhibits after clamping part of its boundary can be represented in graphs relating design objectives and parameters.

8. A method according to claim 1, wherein, as regards step D), the response associated with a point N relative to the choice of the design parameters h.sub.0=H, h.sub.f=0 is obtained for a particular choice of the curvature of the clamping, c=0 corresponding to a flat clamping.

9. A method according to claim 8, wherein by varying the curvature of the clamp it is possible to modify—during the operation of the structure—the value and the ratio between the critical loads F.sub.1,F.sub.2, as well as the shape of the stable equilibrium configurations.

10. A method according to claim 1, wherein, in order to vary the critical transition loads even during the operation of the structure, it provides a clamp with variable curvature: by changing the curvature of the clamp the prestress induced in the shell is modified and with it, its structural response.

11. A method according to claim 1, wherein, having established the response that the shell must provide in the various operating conditions, it comprises determining: the prestress field and the initial geometry therewith, the constitutive properties, the curvature of the clamp to be assigned so that the desired behaviour is guaranteed.

12. A method according to claim 11, wherein the curvature of the clamp can be modified, if necessary, for the supervening of different performance requisites, even during the operation of the structure, by simply appropriately modifying the shape of the clamp.

13. A method according to claim 2, wherein, as regards step A), for composite shells the design parameters representative of the material are the characteristics of the elementary ply and the lamination sequence.

14. A method according to claim 2, wherein, as regards step B), to obtain a discrete approximation of the elastic energy of the shell, comprising the membrane and bending contributions, a polynomial form can be chosen to describe the curvature of the shell in the generic configuration; in this case the configuration parameters being the coefficients q={q.sub.1, q.sub.2, . . . , q.sub.n} of the polynomials describing the curvature of the shell and that, together with the design parameters, define the elastic energy thereof.

15. A method according to claim 3, wherein, as regards step B), to obtain a discrete approximation of the elastic energy of the shell, comprising the membrane and bending contributions, a polynomial form can be chosen to describe the curvature of the shell in the generic configuration; in this case the configuration parameters being the coefficients q={q.sub.1, q.sub.2, . . . , q.sub.n} of the polynomials describing the curvature of the shell and that, together with the design parameters, define the elastic energy thereof.

16. A method according to claim 4, wherein, as regards step B), to obtain a discrete approximation of the elastic energy of the shell, comprising the membrane and bending contributions, a polynomial form can be chosen to describe the curvature of the shell in the generic configuration; in this case the configuration parameters being the coefficients q={q.sub.1,q.sub.2 . . . , q.sub.n} of the polynomials describing the curvature of the shell and that, together with the design parameters, define the elastic energy thereof.

17. A method according to claim 2, wherein, as regards step C), setting the material parameters relating to: characteristics of the elementary ply, lamination sequence, aspect ratio, curvature of the clamping, it is possible to minimize the polynomial approximation of the elastic energy with respect to the configuration parameters and to determine, for each possible choice of curvatures h.sub.0,h.sub.f of the edges x.sub.1=0, L.sub.x of the free shell and for each load level, the number, the shape, the elastic energy etc., of the stable equilibrium configurations that the shell exhibits after clamping its x.sub.1=0 edge, i.e. the design objectives.

18. A method according to claim 3, wherein, as regards step C), setting the material parameters relating to: characteristics of the elementary ply, lamination sequence, aspect ratio, curvature of the clamping, it is possible to minimize the polynomial approximation of the elastic energy with respect to the configuration parameters and to determine, for each possible choice of curvatures h.sub.0,h.sub.f of the edges x.sub.1=0, L.sub.x of the free shell and for each load level, the number, the shape, the elastic energy etc., of the stable equilibrium configurations that the shell exhibits after clamping its x.sub.1=0 edge, i.e. the design objectives.

19. A method according to claim 4, wherein, as regards step C), setting the material parameters relating to: characteristics of the elementary ply, lamination sequence, aspect ratio, curvature of the clamping, it is possible to minimize the polynomial approximation of the elastic energy with respect to the configuration parameters and to determine, for each possible choice of curvatures h.sub.0,h.sub.f of the edges x.sub.1=0, L.sub.x of the free shell and for each load level, the number, the shape, the elastic energy etc., of the stable equilibrium configurations that the shell exhibits after clamping its x.sub.1=0 edge, i.e. the design objectives.

20. A method according to claim 5, wherein, as regards step C), setting the material parameters relating to: characteristics of the elementary ply, lamination sequence, aspect ratio, curvature of the clamping, it is possible to minimize the polynomial approximation of the elastic energy with respect to the configuration parameters and to determine, for each possible choice of curvatures h.sub.0,h.sub.f of the edges x.sub.1=0, L.sub.x of the free shell and for each load level, the number, the shape, the elastic energy etc., of the stable equilibrium configurations that the shell exhibits after clamping its x.sub.1=0 edge, i.e. the design objectives.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other purposes will be better understood from the following detailed description. This description and the associated figures are intended to give a simple, non-exhaustive, example of a shell satisfying the claimed stability properties.

In particular:

[0008] FIG. 1a illustrates the configuration of the structure without external loads;

[0009] FIG. 1b illustrates the possible configurations of the structure in the bistability region;

[0010] FIG. 1c illustrates the equilibrium paths as the load F varies;

[0011] FIG. 2 illustrates the geometric parameters which describe the initial stress-free shape of the shell;

[0012] FIG. 3 illustrates the stability diagrams with respect to the geometric design parameters;

[0013] FIG. 4 illustrates a shell prototype built and tested at Dipartimento di Ingegneria StrutturaLe e Geotecnica (University of Rome “La Sapienza”);

[0014] FIG. 5 illustrates the stability limits as functions of the clamp curvature;

[0015] FIG. 6 illustrates the natural configuration of the free shell corresponding to point N in FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] An example of the suggested bistable structure is described with reference to the figures listed above.

[0017] In its natural stress-free configuration the shell has the shape shown in FIG. 2. Once clamped along the edge x.sub.1=0 highlighted in blue, in absence of load the shell assumes the shape shown in FIG. 1a. If the initial shape is appropriately chosen (as specified below) the shell is prestressed (meaning that each part thereof has a given level of stored elastic energy) but monostable.

[0018] Then, the behavior under load of the shell represented is shown in FIG. 1c in the plane (F,q) with F a load parameter and q a configuration parameter, as outlined below: [0019] 1. subject to a load, e.g. an aerodynamic pressure, the shell deforms following the equilibrium branch Γ.sub.1; [0020] 2. When F=F.sub.1 the branch Γ.sub.1 becomes unstable. By increasing the load even further, the shell leaves branch Γ.sub.1 for branch Γ.sub.2; the transition takes place with an abrupt change of shape. The branch Γ.sub.2 is stable for F>F.sub.2. Therefore, for F.sub.2≤F≤F.sub.1, the shell has two stable equilibrium configurations, FIG. 1b; [0021] 3. by increasing the load, the shell deforms following the branch Γ.sub.2; [0022] 4. by decreasing the load, the shell returns to the branch Γ.sub.1 when F<F.sub.2 and takes the configuration O as the load is completely removed.

[0023] The non-linear equilibrium path of FIG. 1c is completely defined by the shapes that the shell assumes during the steps of loading and unloading (i.e. at low- and high-load regimes) and by the critical transition loads F.sub.1 and F.sub.2 which are the design requirements.

[0024] The described behavior depends on the prestress field acting in the shell in its clamped configuration O.

[0025] A peculiar feature of the present invention is precisely the choice of the prestress field that ensures the desired behaviour when varying the external applied forces.

[0026] It is suggested to induce such prestress state by clamping a shell having an appropriate (stress-free) initial shape.

[0027] Indeed, if the clamping action forces the shell to vary its Gaussian curvature, even locally, the level of prestress induced thereof is proportional to the thickness of the shell; since the bending stiffness is proportional to the cube of the thickness, for thin shells this prestress results in sizeable variations in curvature and shape.

[0028] Specifically, in order to induce the appropriate prestress field in the shell, the following method is applied: [0029] 1. A predetermined curvature is imposed on a portion of the shell edge. This part of the shell edge is then clamped. The prestress obtained by applying the clamp depends on a finite number of design parameters p.sub.i={h.sub.i=1, 2 . . . ;m.sub.i=1, 2 . . . ; c}, with h.sub.i, m.sub.i being representative of the shape of the initial stress-free configuration of the shell and of the material, respectively, and c the curvature of the clamp. For example, shells whose natural stress-free configuration is of the type shown in FIG. 2 have average surface given by the function

[00001]$w_0=\frac{x_2^2}{2}\left[h_0+\left(h_f-h_0\right)\frac{x_1}{L_1}\right]\text{:}$  in this case the design parameters representative of the shape of the free shell are: h.sub.0, the curvature of the edge x.sub.1=0 which will then be clamped to induce the prestress; h.sub.f, the curvature of the opposite edge, which will remain free; L.sub.2/L.sub.1, the planform aspect ratio.  For composite material shells, the representative design parameters of the material are the characteristics of the elementary ply and the lamination sequence. Again as an example, for an eight-layer anti-symmetrical laminate of the type [α/−α/−α/α/−α/α/α/−α], the design parameters are: E.sub.1,E.sub.2,G.sub.12,v.sub.12, the properties of the elementary ply; t.sub.i, the thickness of the elementary ply; α, the lamination angle.  Thus, in this case, the prestress in the shell will depend on the choice of ten design parameters p={h.sub.0,h.sub.1,L.sub.2/L.sub.1;E.sub.1,E.sub.2,G.sub.12,v.sub.12,t.sub.i,α;c}. Of these, the last, i.e. the curvature of the clamp c to be assigned to the edge x.sub.1=0 can be modified in operation. [0030] 2. A discrete shell model is defined by projecting the non-linear shell model of Marguerre-von Kármán onto an appropriate finite dimensional space. The projection infers a discrete model with a few number of configuration parameters q.sub.i, (i<5) and does not significantly alter the elastic energy of the shell; models of this type are described, for example, in scientific papers [12, 13]. For example, a suitable polynomial approximation of the elastic energy of the shell including membrane and bending contributions is found by choosing a polynomial form to describe the shell shape in the generic configuration and following the procedure described in detail in [13]. In this case, the configuration parameters are the coefficients q={q.sub.1, q.sub.2, . . . , q.sub.n} of the polynomials describing the curvature of the shell. Together with the design parameters, they define the elastic energy of the discrete shell model. [0031] 3. With the discrete representation of the elastic energy E(q;p) obtained it is possible to compute the stability maps in the space of the design parameters; for every choice of the design parameters; this allows to determine the number and the shape of the stable equilibrium configurations that the clamped shell has at each value of the applied load. For example, having fixed the material parameters (the properties of the elementary ply and the lamination sequence), the aspect ratio and the curvature of the clamp, it is possible to minimize the polynomial shape that approximates the elastic energy with respect to the configuration parameters and to determine, for each possible choice of the shell initial curvatures h.sub.0,h.sub.f of the edges x.sub.1=0,L.sub.x (FIG. 2), and for each value of the applied load, the number, the shape, the elastic energy, etc., of the stable equilibrium configurations that the shell exhibits after clamping, i.e. the design objectives. These informations can be summarized in plots of the type shown in FIG. 3, which relate objectives and project parameters (in this case, curvatures h.sub.0,h.sub.f) for different load values. [0032] 4. Finally, the design parameters are chosen so as to provide the prestress needed to obtain the desired response in terms of project requirements. For example, the response described in FIG. 1 is the one associated with point N of FIG. 3, i.e. the choice of the project parameters h.sub.0=H, h.sub.f=0 which correspond to the initial stress-free configuration of FIG. 6. The response in FIG. 1 is obtained by considering the particular choice of the clamping curvature c=0 (that is, a flat clamp). By varying the latter, it is possible to tune either the value and ratio between the critical loads F.sub.1,F.sub.2, as well as the shape of the stable equilibrium configurations, even during operation. For example, for point N the critical loads vary with the curvature of the clamp as shown in FIG. 5.

[0033] With the method described above it is possible to: [0034] A) design the shapes that the shell must take during the loading process according to the performance requirements; [0035] B) set the load values at which the transition occurs, by choosing a point that has only one stable configuration for F=0, two for F.sub.2≤F≤F.sub.1 and again one for F>F.sub.1; [0036] C) tune the critical transition loads also during structural operation; [0037] D) identify the optimized shape of the shell when free from constraints.

[0038] In order to achieve the latter goal, according to a further peculiar characteristic of the invention, a clamping with tunable curvature is provided: by changing the curvature of the clamp the prestress induced in the shell is modified, and its structural response therewith, so as to meet the performance requirements of the moment. By way of non-limiting example, the curves in FIG. 5 represent the law according to which the critical transition loads F.sub.1 and F.sub.2 vary as the curvature assigned to the clamp varies (this latter normalised with respect to the initial curvature of the edge to be clamped). It is worth noting that also with modest variations in the curvature of the clamping it is possible to radically change the structural response, moving the critical load values closer or further apart.

[0039] In other words: once the performance requirements that the shell must guarantee have been decided (for example, the optimal geometrical configurations to be assumed in the various speed regimes and the critical velocity values), the method in the present invention makes it possible to determine the prestress field, that is, the initial geometry, the constitutive properties (e. g. the type of elementary ply and the lamination sequence) and the curvature of the clamp, to be chosen so that the performance requirements can be fulfilled; if necessary these latter can also be modified, even during the operation of the structure, simply by appropriately modifying the curvature, i. e. the shape, of the clamp.

[0040] The prototype in FIG. 4 was made for experimental purposes: in FIG. 4a, the free shell, before the application of the clamp (the shape is of the type shown in FIG. 2, with h.sub.0≃15 m.sup.−1, h.sub.f=0 m.sup.−1); in FIG. 4b, the configuration assumed by the shell after the imposition of the clamp, in this case flat (c=0); in FIGS. 4c and 4d, the two stable equilibrium configurations that the shell can assume for F.sub.2≤F≤F.sub.1.

[0041] The shell of this invention can adapt its shape autonomously to the load applied in order to meet predetermined performance requirements and maximize structural efficiency (e.g. it can be used as a component to improve the aerodynamic performance of a vehicle). The shell has a shape at low-load regimes (e.g. the most suitable for low speeds) and a different shape, even significantly different, at high-load regimes (e.g. the most suitable for high speeds), wherein the change of shape occurs spontaneously as the load varies.

[0042] By virtue of the above, the present invention provides at least the following advantages:

[0043] 1. no actuating energy other than that supplied by the load directly acting on the shell is required; therefore, it is not necessary to provide actuators;

[0044] 2. unlike traditional bistable structures, the shell returns to its original shape when the load is removed with no need for external intervention: in all cases, the equilibrium path is closed, i.e. the reversibility of the transformation is ensured;

[0045] 3. the design concerns both the shapes required during loading and unloading and the critical transition load values, i.e. all the parameters that define the equilibrium path;

[0046] 4. the possibility of varying the curvature of the clamp makes it possible to modify stable shapes and transition loads, even while the structure is in operation.

[0047] Because of its ability to be efficient under radically different operating conditions, the present invention has many possibilities for use in various areas of industrial engineering, e.g. in the manufacture of morphing aerodynamic appendages, and in civil engineering, e.g. in the manufacture of building envelopes and adaptive ventilation systems. In the field of industrial engineering, in particular, the invention is a reliable and cost-effective solution. Indeed, it is not necessary to supply power to the system nor is it necessary to use gear systems or other means, because:

[0048] A. the transition between the different structural forms is induced by external load itself;

[0049] B. the maintenance of each of them is ensured by its stability.

In conclusion, it is useful to point out that, according to the present invention, the shell is not initially prestressed: only with the application of the constraint the appropriate prestress field is induced within it.
Inter alia, this prestress is a function of the natural stress-free shape of the shell, i.e. the shape of the shell when it is free of external constraints, i.e. before it is clamped at one end.

[0050] Furthermore, according to the invention, the shape of the shell in the stress-free configuration is a fundamental parameter to be optimized (along with the constitutive properties of the material), which is not given a priori but has to be chosen on the basis of the design requirements: the critical transition loads and the optimal shell shapes for low- and high-load regimes.

LITERATURE

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