Hagnell M K, Kumaraswamy S, Nyman T, Åkermo M
Department of Aeronautical and Vehicle Engineering, KTH Royal Institute of Technology, Stockholm, Sweden.
Volvo Car Corporation, Göteborg, Sweden.
Heliyon. 2020 Mar 31;6(3):e03716. doi: 10.1016/j.heliyon.2020.e03716. eCollection 2020 Mar.
The design of a composite material structure is often challenging as it is driven by the trade-off between lightweight performance and production costs. In this paper, the boundaries of this design trade-off and its implications on material selection, geometrical design and manufacturability are analysed for a number of design strategies and composite material systems. The analysis is founded on a methodology that couples weight-optimization and technical cost modelling through an application-bound design cost. Each design strategy is evaluated for three levels of bending and torsional stiffness. The resulting stiffness-versus cost-range together constructs the design envelope and provides guidelines on the suitability and improvement potential of each case. Design strategies researched include monolithic, u-beam-, sandwich-insert- and sandwich-stiffened plates. Considered material systems include carbon-, glass, recycled carbon-, lignin- and hemp-fibre reinforced composites. Optimized sandwich designs are shown to have lowest design cost. Glass-, recycled carbon-, lignin- and hemp-fibre reinforced composite materials are all shown to reduce costs but at lower stiffness performance. Ultimately, the case study demonstrates the importance of early structural design trade-off studies and material selection and justifies introducing novel fibre systems in low-cost applications of moderate stiffness levels.
复合材料结构的设计往往具有挑战性，因为它受到轻量化性能和生产成本之间权衡的驱动。本文针对多种设计策略和复合材料系统，分析了这种设计权衡的边界及其对材料选择、几何设计和可制造性的影响。该分析基于一种通过应用约束设计成本将重量优化与技术成本建模相结合的方法。对每种设计策略在三个弯曲和扭转刚度级别上进行评估。由此产生的刚度与成本范围共同构成了设计包络，并为每种情况的适用性和改进潜力提供了指导。研究的设计策略包括整体式、U型梁式、夹层插入式和夹层加劲板。考虑的材料系统包括碳、玻璃、回收碳、木质素和麻纤维增强复合材料。优化后的夹层设计显示出最低的设计成本。玻璃、回收碳、木质素和麻纤维增强复合材料都显示出能降低成本，但刚度性能较低。最终，该案例研究证明了早期结构设计权衡研究和材料选择的重要性，并证明了在中等刚度水平的低成本应用中引入新型纤维系统的合理性。
