This study investigates the curing deformation and drilling effects in composite hat-shaped stiffened panels, which are widely used in aerospace structures for their high strength-to-weight ratio. A numerical path-dependent constitutive model was developed to simulate the curing process, demolding, and drilling operations using ABAQUS, with experimental validation conducted via laser scanning on a full-scale AS4/8552 composite panel (radius: 3000 mm, length: 2000 mm). The results show that the curing deformation exhibits a distinct “X” shape, with a maximum out-of-plane deformation of 2.48 mm in the center and downward edges. Secondary drilling significantly reduced the curing deformation through residual stress relief, whereas pre-reserved holes markedly increased deformation due to stress concentration and reduced stiffness, as confirmed by both experimental and simulation results. Furthermore, an optimal hole size of 300 × 200 mm (3% of panel area) minimized deformation, while larger holes (e.g. 700 × 600 mm) led to a 49.5% reduction in buckling load and increased distortion. These findings provide quantitative guidance for optimizing manufacturing processes to balance stress release and structural integrity in composite stiffened panels.
Liu et al. (Fri,) studied this question.
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