Optimisation of structural components is being increasingly used to enhance their durability and operational life, improve load carrying capacity and reduce the loss of structural integrity. Conventional optimisation approaches are mostly aimed at reducing the peak stress in a structure and do not consider the inevitable presence of defects or cracks. The aim of this course is to provide knowledge and expertise in design, analysis and optimisation of engineering structures based on damage tolerance parameters, including residual strength and fatigue life, as the design objectives. ‘Damage Tolerance Optimisation’ provides the know-how to utilise the power of high-performance computing and structural integrity (fatigue/fracture) analysis tools to augment the design and optimisation capabilities of end-users. Learning Objectives 1. Understand the basic concepts and underlying principles of damage tolerance design philosophy and damage tolerance parameters – residual strength and fatigue life. 2. Demonstrate an understanding of the usage of different material systems (metals and composites) in aerospace, transport, automotive, maritime, biomedical and allied applications. 3. Evaluate the fracture and fatigue performance criteria and the respective assessment techniques for metallic and composite structural components. 4. Assess the difference in the fracture behaviour and fatigue properties of additive manufactured metal and composite components compared to those fabricated by conventional manufacturing methods. 5. Synthesise and formulate methodologies for optimisation based on various damage tolerance parameters as the design objectives. 6. Apply damage tolerance design and optimisation techniques to current and emerging engineering applications in the aerospace, transport, automotive, marine, and biomedical industries.

Guest Lectur: Prof Raj Das Group Leader, Simulation of Advanced Materials and Structures (SAMS) Group Full Professor of Aerospace Engineering and Aviation, School of Engineering, RMIT University, Melbourne, Australia. Day 1: Lectures 1-2 (2 hours) Lecture 1: 1 hour Module 1: Damage Tolerance Approach in Structural Analysis and Design Content: • Brief background of damage tolerance assessment from historical perspectives. • Comparison and distinction between the conventional mechanical design and damage tolerance design. • Challenges and opportunities in damage tolerance based design approach. Lecture 2: 1 hour Module 2: Introduction to Structural Shape Optimisation Content: • Core principles of shape optimisation and associated different methods. • Optimisation parameters: Objective functions, constraints, and design variables. • Application of shape optimisation to strength based design via minimising stress concentration. Day 1: Lectures 1-2 (2 hours) Lecture 1: 1 hour Module 1: Damage Tolerance Approach in Structural Analysis and Design Content: • Brief background of damage tolerance assessment from historical perspectives. • Comparison and distinction between the conventional mechanical design and damage tolerance design. • Challenges and opportunities in damage tolerance based design approach. Lecture 2: 1 hour Module 2: Introduction to Structural Shape Optimisation Content: • Core principles of shape optimisation and associated different methods. • Optimisation parameters: Objective functions, constraints, and design variables. • Application of shape optimisation to strength based design via minimising stress concentration. Day 2: Lectures 3-4 (2 hours) Lecture 3: 1 hour Module 3: Design and Optimisation for Additive Manufacturing Content: • Relationship between design and optimisation for additive manufactured components. • Optimising lightweight designs for manufacturability using additive manufacturing of composites. Lecture 4: 1 hour Module 4: Damage Tolerance and Structural Integrity of Metallic Structures Content: • Characterisation and assessment of the severity of flaws (defects, cracks, and damage) in metals. • Identification of critical damage tolerance parameters including load spectrum analysis. • Fracture and fatigue evaluation of critical metallic components and their implications for design process. Day 3: Lectures 5-6 and Tutorial 1 (3 hours) Lecture 5: 1 hour Module 5: Damage Tolerance Assessment and Fatigue of Additive Manufactured Components Content: • Characteristics of flaws (defects, cracks, and damage) in AM materials. • Effect of AM process parameters on microstructure and defects. • Effect of post-processing operations on fatigue properties. Lecture 6: 1 hour Module 6: Damage Tolerance Assessment of Composite Structures Content: • Characteristics of flaws (defects, cracks, and damage) in composites. • Fracture mechanics in composite laminates and sandwiches. • Failure analysis of composite laminate and sandwich structures. Tutorial 1: 1 hour Tutorial 1: Fracture Mechanics and Fatigue Life Evaluation Techniques for Metallic Components Content: • Hands-on damage tolerance evaluation for simple benchmark problems using fracture mechanics via calculation of stress intensity factors for different crack configurations using simple spreadsheets or Python program. • Evaluation of fatigue life by employing common crack growth equations for different types of cyclic loading conditions such as constant and variable amplitude loadings using simple spreadsheets or Python program. Day 4: Lectures 7-8 (2 hours) Lecture 7: 1 hour Module 7: Fatigue Evaluation of Composite Structures Content: • Concepts of fatigue in composites in relation to defects and loading. • Difference between fatigue in metals and composites from physical mechanism perspectives. • Methods and tools for fatigue life assessment of composites. Lecture 8: 1 hour Module 8: Structural Design and Optimisation with Residual Strength and Fatigue Life as Design Objectives Content: • Residual strength optimisation: Formulation, methodology and results using simple benchmark problems. • Fatigue life optimisation: Formulation, methodology and results using simple benchmark problems. Day 5: Lectures 9-10 and Tutorial 2 (3 hours) Lecture 9: 1 hour Module 9: Concepts and Methodologies for Structural Optimisation based on Damage Tolerance Content: • Concepts of optimisation versus parametric studies in structural design. • Different methodologies for structural optimisation of engineering structures. • Damage tolerance optimisation – objective and constraint functions. Lecture 10: 1 hour Module 10: Design Guidelines and Case Studies for Damage Tolerance Optimisation Content: • Aerospace application: Real-world examples of damage tolerance optimisation for aircraft and spacecraft components. • Automotive application: Applying damage tolerance optimisation to improve vehicle safety and efficiency Tutorial 2: 1 hour Tutorial 2: Practical Implementation of Optimisation based on Damage Tolerance Constraints Content: • Analysis and optimisation of metallic and composite laminates and structures using Python based in-house optimisation program. • Implementation of optimisation procedure incorporating explicit damage tolerance parameters – residual strength and fatigue life. • Demonstration through engineering case studies – aerospace, marine, transport, etc.

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P.D.1-1 - Dicembre

December 2 | 9 - 12 | 14 - 17 December 3 | 9 - 12 | 14 - 17 Meeting Room 3rd floor DIMEAS