Dual-scale parametric modeling and optimal design method of CFRP automotive roof beam

Lv, Tiantong; Wang, Dengfeng; Du, Xueming

doi:10.1016/j.compstruct.2023.116695

Cited by 6 publications

(4 citation statements)

References 34 publications

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“…Carbon composite materials are now being employed in the aerospace industry [1][2][3][4][5][6][7][8]. Recently, carbon fiber reinforced plastics (CFRP) have been used in automobiles [9,10] because they provide specific energy absorption through the expression of compressive fracturing and delamination [11,12]. To apply CFRP, compressive failure should be carefully considered, as a proper estimation of the compressive strength allows for the efficient design of structures.…”

Section: Introductionmentioning

confidence: 99%

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Enhanced Estimation of Axial Compressive Strength for CFRP Based on Microscale Numerical Simulation and the Response Surface Method

Yoshida,

Deng,

Koyanagi

2024

Materials

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Compressive strength is one of the most important properties of carbon fiber reinforced plastics (CFRP). In this study, a new method for predicting the axial compressive strength of CFRP using the response surface method is developed. We focused on a microbuckling model to predict the compressive strength of unidirectional fiber composites. For the microbuckling model, axial shear properties are required. To obtain the compressive strength for various material properties, we perform individual shear tests and numerical simulations, but these require enormous computational costs and extended time. To address the issue of computational cost, in this study, we propose a new method to predict compressive strength using the response surface method. First, we perform shear simulation in a microscale fracture model for unidirectional CFRP with various parameters of the fiber and resin properties. Based on the results of the shear simulation, the response surface method is used to evaluate and develop prediction equations for the shear properties. This method allows for the study of the objective values of the parameters, without significant computational effort. By comparing both the results predicted from the response surface method (RSM) and the simulation results, we verify the reliability of the prediction equation. As a result, the coefficient of determination was higher than 94%, and the validity of the prediction method for the compressive strength of CFRP using the response surface method (RSM) developed in this study was confirmed. Additionally, we discuss the material properties that affect the compressive strength of composites comprised of fibers and resin. As a result, we rank the parameters as follows: fiber content, elastic modulus after resin yield, yield stress, and initial elastic modulus.

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Section: Introductionmentioning

confidence: 99%

“…The coefficients of the function were statistically estimated using the least squares method. The RSM calculations are shown in Equation (9).…”

mentioning

confidence: 99%

Enhanced Estimation of Axial Compressive Strength for CFRP Based on Microscale Numerical Simulation and the Response Surface Method

Yoshida,

Deng,

Koyanagi

2024

Materials

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“…Hou et al [14] proposed a multi-objective design optimization methodology on geometry and lay-ups for CFRP structure, achieving a T-joint with reduced weight and improved overall stiffness and strength behavior. Lv et al [22] took the structural shape of CFRP parts as the macroscopic design parameters and the lamination scheme as the mesoscale design parameters, and established a dual-scale fullparameter model to carry out the optimal design of the roof beam, and effectively reduced the quality and improved the strength of the roof beam.…”

Section: Introductionmentioning

confidence: 99%

Geometry optimization on the cross section of adhesively bonded thin-walled composite beam subjected to axial crushing load

Xiao,

Ye,

Hou

et al. 2024

Academia Materials Science

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Adhesive bonding is widely used in structural connection of composite components due to its capacity to effectively avoid inducing stress concentration and damage in composite components. This work applies a design optimization methodology on the geometry of cross section and ply thickness in adhesively bonded CFRP (carbon fiber-reinforced plastic), hat-shaped, thin-walled beam in automobiles to achieve car body lightweight design. A multi-objective and multi-constraint design optimization problem was formulated to find the optimum key cross-section size and ply thickness of the hat thin-walled beam. The minimum total material cost and maximum energy absorption (EA) during the axial crushing test of the CFRP beam were selected as the optimization objectives. The non-dominated sorting genetic algorithm II (NSGA-II) was introduced to search for global optimum solution, and radial basis function (RBF) approximations for the objective functions were applied to reduce the computational cost. It was revealed that EA increased by 8.28%, while the total weight and cost decreased by 3.14% and 3.23%, respectively, and can thus provide a guidance in vehicle composite component design.

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“…Due to their excellent corrosion resistance, specific strength and modulus, CFRPs are being widely utilized in the aerospace [ 1 , 2 ], automotive [ 3 , 4 ], construction industries [ 5 , 6 ], lightweight structures [ 7 , 8 ] and military fields [ 9 , 10 ]. Differing from conventional materials, CFRPs usually consist of a polymer matrix and fibers [ 11 ], in which the polymer matrix usually exhibits visco-elastic behavior [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

Micro-Scale Numerical Simulation of Fatigue Failure for CFRP Subjected to Multiple-Amplitude Cyclic Loadings Based on Entropy Damage Criterion

Deng,

Toda,

Sato

et al. 2023

Materials

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Fatigue failure of carbon fiber-reinforced plastics (CFRPs) under cyclic loadings has attracted the attention of researchers recently. In this study, the entropy-based failure criterion is proposed to investigate the fatigue lifetime of unidirectional CFRPs subjected to multiple-amplitude cyclic loadings. Due to the heterogeneity of CFRPs, a micro-finite element model considering matrix resin and fibers independently is developed, and the entropy-based damage criterion is implemented into a user-subroutine of Abaqus to model the progressive damage of matrix resin. The fatigue lifetime of CFRPs under typical loading sequences consisting of two stages, such as varying from low to high (L-H) or from high to low (H-L) loading sequence, is estimated with the proposed failure criterion. Numerical results show that the initial damage occurs near the area between two fibers, and a transverse crack propagates progressively under the cyclic loading. The difference in predicted lifetime to final failure in L-H and H-L stress levels is 6.3%. Thus, the effect of loading sequence on the fatigue lifetime can be revealed via the proposed entropy-based damage criterion. Comparisons with the conventional linear cumulative damage (LCD) and kinetic crack growth (KCG) theories are also conducted to demonstrate the validity of the proposed method. The entropy-based failure criterion is a promising method to predict the residual strength and fatigue lifetime of CFRP components.

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Dual-scale parametric modeling and optimal design method of CFRP automotive roof beam

Cited by 6 publications

References 34 publications

Enhanced Estimation of Axial Compressive Strength for CFRP Based on Microscale Numerical Simulation and the Response Surface Method

Enhanced Estimation of Axial Compressive Strength for CFRP Based on Microscale Numerical Simulation and the Response Surface Method

Geometry optimization on the cross section of adhesively bonded thin-walled composite beam subjected to axial crushing load

Micro-Scale Numerical Simulation of Fatigue Failure for CFRP Subjected to Multiple-Amplitude Cyclic Loadings Based on Entropy Damage Criterion

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