A global sensitivity analysis approach for designing high-performance braided thermoplastic composites: A case study of braided carbon fiber reinforced poly ether ether ketone

Designing superior braided thermoplastic composites that account for uncertainties in internal structural parameters (SPs) and material properties (MPs) can enhance the mechanical properties of integrated structural components. This study proposes a novel approach to design high-performance Braided Carbon Fiber Reinforced Poly Ether Ether Ketone (BCF/PEEK) using computational analysis to assess variability in SPs and MPs, and determine the sensitivity of fiber and Poly Ether Ether Ketone (PEEK). Initially, a large dataset of parameter samples for sensitivity analysis is acquired using a command stream-driven finite element (FE) method, employing the scale-span mechanical property characterization model of BCF/PEEK. Subsequently, Grey Relation Analysis (GRA) of SPs for BCF/PEEK is performed to establish an optimal prediction model. Then, a global sensitivity analysis model for MPs of the carbon fiber and PEEK is developed and solved using MATLAB software, along with input and output sample sets. An innovative approach is proposed, employing variable parameter amplitudes to validate the sensitivity coefficients of MPs. Various BCF/PEEK configurations that can withstand different types of loads are designed using the developed sensitivity analysis model. Finally, the strong correlation of MPs in BCF/PEEK is confirmed using the scale-span FE characterization model, validating the accuracy and efficiency of the proposed design approach.