Warpage of Large Curved Composite Panels due to Manufacturing Anomalies

This paper discusses the influences of a misaligned layer, a resin-rich slightly thicker layer, and a small thermal gradient on the thermally-induced deformations of large curved composite panels during cooldown from their cure temperature. The deformations represent warpage of the panels due to anomalies that occur during layup, consolidation, and cure. Two-dimensional finite element analyses are used The deformations are categorized as to their impact on circumferential and twist warpage metrics. The results are intended to highlight the sensitivity of manufactured panel shape to the various unwanted effects that can occur during manufacturing.