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Design and Optimization of Composite Automotive Hatchback Using Integrated Material-Structure-Process-Performance Method

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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 “material-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%.

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Acknowledgements

Xudong Yang and Lingyu Sun would like to thank the support from the National Natural Science Foundation of China (No. U1664250 and No. 51575023). Lingyu Sun and Lijun Li would like to thank the support from the National Key Research and Development Program of China (No. 2016YFB0101606). Lijun Li would like to thank the Joint Fund of China Shipbuilding Industry Corporation (CSIC) Equipment Pre-research (No. 6141B04010403).

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Authors and Affiliations

  1. School of Transportation Science and Engineering, Beihang University, 37 Xueyuan Road, Haidian District, Bei**g, 100191, China

    Xudong Yang, Lingyu Sun, Cheng Zhang & Lijun Li

  2. Lightweight Vehicle Innovation Center, Beihang University, 37 Xueyuan Road, Haidian District, Bei**g, 100191, China

    Xudong Yang, Lingyu Sun, Cheng Zhang & Lijun Li

  3. The 713 Research Institute of China Shipbuilding Industry Corporation, Zhengzhou, Henan, 450015, China

    Zongmiao Dai & Zhenkai **ong

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  1. Xudong Yang
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  2. Lingyu Sun
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  3. Cheng Zhang
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  4. Lijun Li
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  5. Zongmiao Dai
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Correspondence to Lijun Li.

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Yang, X., Sun, L., Zhang, C. et al. Design and Optimization of Composite Automotive Hatchback Using Integrated Material-Structure-Process-Performance Method. Appl Compos Mater 25, 1455–1475 (2018). https://doi.org/10.1007/s10443-018-9677-1

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  • DOI: https://doi.org/10.1007/s10443-018-9677-1

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