Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile
In order to improve the lightweight level of the automotive floor, reduce material application cost, and improve integrated process manufacturing performance through structural design and optimization, this article proposes a design method to link conceptual design and detailed design and optimize t...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-11-01
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| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/14/21/4768 |
| _version_ | 1797466716136013824 |
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| author | Shuai Zhang Hao Song Liyou Xu Kefang Cai |
| author_facet | Shuai Zhang Hao Song Liyou Xu Kefang Cai |
| author_sort | Shuai Zhang |
| collection | DOAJ |
| description | In order to improve the lightweight level of the automotive floor, reduce material application cost, and improve integrated process manufacturing performance through structural design and optimization, this article proposes a design method to link conceptual design and detailed design and optimize the composite floor by combining free size optimization and size optimization methods. The basic theory of composite mechanics is expounded from the stress-strain theory of single-layer plates, and the stiffness and strength theory of laminated plates, which provides theoretical support for the structural design, material design, and allowable value design of composites. The mechanical properties of CFRP were tested to obtain the basic material parameters of CFRP T300/5208. With the material parameters, the CFRP floor super layers are established in Optistruct software. The shape of the floor super layers is optimized by using the free size optimization method, with the body-in-white (BIW) lightweight coefficient as the objective and the BIW performance as the constraints. The BIW lightweight coefficient is reduced from 4.35 to 4.20 after free size optimization, and the layer blocks shape is obtained and clipped based on engineering application. With the floor mass as the objective and the BIW performance as the constraints, the size optimization of the floor layer blocks thickness is optimized. Then the number of floor layers is obtained, and the CFRP floor is established in Fibersim software. Use the simulation analysis method to compare and verify the performance of the floor before and after optimization. The results show that the failure index of the floor is far less than the failure standard, while the mass of the CFRP floor is reduced by 6.8 kg compared with the original steel floor, which an improvement rate reaching 27.5%. The design and optimization methods presented in this article provide a reference for the design and application of the CFRP floor. |
| first_indexed | 2024-03-09T18:43:40Z |
| format | Article |
| id | doaj.art-fbb9700096414e0ab0d3fa339d3f60fb |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-09T18:43:40Z |
| publishDate | 2022-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-fbb9700096414e0ab0d3fa339d3f60fb2023-11-24T06:31:35ZengMDPI AGPolymers2073-43602022-11-011421476810.3390/polym14214768Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for AutomobileShuai Zhang0Hao Song1Liyou Xu2Kefang Cai3College of Vehicle and Traffic Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaCollege of Vehicle and Traffic Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaCollege of Vehicle and Traffic Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaZ-One Technology Co., Ltd., Shanghai 201800, ChinaIn order to improve the lightweight level of the automotive floor, reduce material application cost, and improve integrated process manufacturing performance through structural design and optimization, this article proposes a design method to link conceptual design and detailed design and optimize the composite floor by combining free size optimization and size optimization methods. The basic theory of composite mechanics is expounded from the stress-strain theory of single-layer plates, and the stiffness and strength theory of laminated plates, which provides theoretical support for the structural design, material design, and allowable value design of composites. The mechanical properties of CFRP were tested to obtain the basic material parameters of CFRP T300/5208. With the material parameters, the CFRP floor super layers are established in Optistruct software. The shape of the floor super layers is optimized by using the free size optimization method, with the body-in-white (BIW) lightweight coefficient as the objective and the BIW performance as the constraints. The BIW lightweight coefficient is reduced from 4.35 to 4.20 after free size optimization, and the layer blocks shape is obtained and clipped based on engineering application. With the floor mass as the objective and the BIW performance as the constraints, the size optimization of the floor layer blocks thickness is optimized. Then the number of floor layers is obtained, and the CFRP floor is established in Fibersim software. Use the simulation analysis method to compare and verify the performance of the floor before and after optimization. The results show that the failure index of the floor is far less than the failure standard, while the mass of the CFRP floor is reduced by 6.8 kg compared with the original steel floor, which an improvement rate reaching 27.5%. The design and optimization methods presented in this article provide a reference for the design and application of the CFRP floor.https://www.mdpi.com/2073-4360/14/21/4768carbon fiber reinforced polymers (CFRP)automobile floormaterial performance testintegrated structural designstructure layer design |
| spellingShingle | Shuai Zhang Hao Song Liyou Xu Kefang Cai Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile Polymers carbon fiber reinforced polymers (CFRP) automobile floor material performance test integrated structural design structure layer design |
| title | Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile |
| title_full | Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile |
| title_fullStr | Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile |
| title_full_unstemmed | Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile |
| title_short | Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile |
| title_sort | application research on the lightweight design and optimization of carbon fiber reinforced polymers cfrp floor for automobile |
| topic | carbon fiber reinforced polymers (CFRP) automobile floor material performance test integrated structural design structure layer design |
| url | https://www.mdpi.com/2073-4360/14/21/4768 |
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