An improved analytical solution for process-induced residual stresses and deformations in flat composite laminates considering thermo-viscoelastic effects

Dimensional control can be a major concern in the processing of composite structures. Compared to numerical models based on finite element methods, the analytical method can provide a faster prediction of process-induced residual stresses and deformations with a certain level of accuracy. It can explain the underlying mechanisms. In this paper, an improved analytical solution is proposed to consider thermo-viscoelastic effects on residual stresses and deformations of flat composite laminates during curing. First, an incremental differential equation is derived to describe the viscoelastic behavior of composite materials during curing. Afterward, the analytical solution is developed to solve the differential equation by assuming the solution at the current time, which is a linear combination of the corresponding Laplace equation solutions of all time. Moreover, the analytical solution is extended to investigate cure behavior of multilayer composite laminates during manufacturing. Good agreement between the analytical solution results and the experimental and finite element analysis (FEA) results validates the accuracy and effectiveness of the proposed method. Furthermore, the mechanism generating residual stresses and deformations for unsymmetrical composite laminates is investigated based on the proposed analytical solution.