Design and Optimization of Composite Automotive Hatchback Using Integrated Material-Structure-Process-Performance Method
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Design and Optimization of Composite Automotive Hatchback Using Integrated Material-Structure-Process-Performance Method Xudong Yang 1,2 & Lingyu Sun 1,2 & Cheng Zhang 1,2 & Lijun Li 1,2 & Zongmiao Dai 3 & Zhenkai Xiong 3
Received: 26 January 2018 / Accepted: 13 February 2018 # Springer Science+Business Media B.V., part of Springer Nature 2018
Abstract The application of polymer composites as a substitution of metal is an effective approach to reduce vehicle weight. However, the final performance of composite structures is determined not only by the material types, structural designs and manufacturing process, but also by their mutual restrict. Hence, an integrated Bmaterial-structure-process-performance^ method is proposed for the conceptual and detail design of composite components. The material selection is based on the principle of composite mechanics such as rule of mixture for laminate. The design of component geometry, dimension and stacking sequence is determined by parametric modeling and size optimization. The selection of process parameters are based on multi-physical field simulation. The stiffness and modal constraint conditions were obtained from the numerical analysis of metal benchmark under typical load conditions. The optimal design was found by multi-discipline optimization. Finally, the proposed method was validated by an application case of automotive hatchback using carbon fiber reinforced polymer. Compared with the metal benchmark, the weight of composite one reduces 38.8%, simultaneously, its torsion and bending stiffness increases 3.75% and 33.23%, respectively, and the first frequency also increases 44.78%. Keywords Integrated design . Composite materials . Optimization . Process simulation . Finite element method . Automotive
* Lijun Li [email protected]
1
School of Transportation Science and Engineering, Beihang University, 37 Xueyuan Road, Haidian District, Beijing 100191, China
2
Lightweight Vehicle Innovation Center, Beihang University, 37 Xueyuan Road, Haidian District, Beijing 100191, China
3
The 713 Research Institute of China Shipbuilding Industry Corporation, Zhengzhou, Henan 450015, China
Appl Compos Mater
1 Introduction Fiber-reinforced polymer composite are gradually being widely used in automotive industry with its excellent performance and lighter weight compared with steel. However, it is difficult to predict the component performance because it is dependent on the material properties, structural design and manufacturing process which restrict mutually. Additionally, the anisotropy of material and simultaneous formability of structure and material increase the difficulty of integrated design. The relationships between performance and other three factors, materials [1–3], structure [4, 5] and manufacturing process [6–8], have been studied separately. But the influence of a certain factor alone on performance neglect the interaction among these four factors in the design process [9, 10], which increase the number of infeasible designs and optimization iteration
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