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In this work, we used finite element analysis method (FEA), response surface methodology (RSM), and Sobol sensitivity analysis method to investigate the factors affecting the spring-in of U-shaped composite parts with drop-off plies. A FEA was introduced to calculate the spring-in, and demonstrated by two case parts of T300/8552 and T800/AC531. A mathematical model based on FEA-RSM was established by analyzing flange parameters, material properties, the size of the drop-off area, and its distance from the cross-section. In addition, all the factors were compared and ranked by sensitivity analysis. Finally, the parameters of the drop-off area were optimized.

Analysis of spring-in of U-shaped composite parts with drop-off plies by FEA-RSM