Xie Wei, Song Kai, Yang Ju, Wang Fengyu, Dong Linjie, Jin Shengjie, Zhu Guohua, Wang Zhen
State Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, China.
School of Automobile, Chang'an University, Xi'an 710064, China.
Polymers (Basel). 2024 Oct 15;16(20):2905. doi: 10.3390/polym16202905.
Carbon fiber reinforced polypropylene (CF/PP) thermoplastics integrate the superior formability of fabrics with the recoverable characteristics of polypropylene, making them a pivotal solution for achieving lightweight designs in new energy vehicles. However, the prevailing methodologies for designing the structural performance of CF/PP vehicular components often omit the constraints imposed by the manufacturing process, thereby compromising product quality and reliability. This research presents a novel approach for developing a stamping-bending coupled finite element model (FEM) utilizing ABAQUS/Explicit. Initially, the hot stamping simulation is implemented, followed by the transmission of stamping information, including fiber yarn orientation and fiber yarn angle, to the follow-up step for updating the material properties of the cured specimen. Then, the structural performance analysis is conducted, accounting for the stamping effects. Furthermore, the parametric study reveals that the shape and length of the blank holding ring exerted minimal influence on the maximum fiber angle characteristic. However, it is noted that the energy absorption and crushing force efficiency metrics of the CF/PP specimens can be enhanced by increasing the length of the blank holding ring. Finally, a discrete optimization design is implemented to enhance the bending performance of the CF/PP specimen, accounting for the constraint of the maximum shear angle resulting from the stamping process. The optimized design resulted in a mass reduction of 14.3% and an improvement in specific energy absorption () by 17.5% compared to the baseline sample.
碳纤维增强聚丙烯（CF/PP）热塑性塑料将织物优异的可成型性与聚丙烯的可回收特性相结合，使其成为实现新能源汽车轻量化设计的关键解决方案。然而，目前用于设计CF/PP车辆部件结构性能的方法往往忽略了制造工艺所带来的限制，从而影响了产品质量和可靠性。本研究提出了一种利用ABAQUS/Explicit开发冲压-弯曲耦合有限元模型（FEM）的新方法。首先进行热冲压模拟，然后将包括纤维纱线取向和纤维纱线角度在内的冲压信息传递到后续步骤，以更新固化试样的材料属性。接着，考虑冲压效应进行结构性能分析。此外，参数研究表明，压边圈的形状和长度对最大纤维角度特性影响最小。然而，值得注意的是，通过增加压边圈的长度，可以提高CF/PP试样的能量吸收和压溃力效率指标。最后，考虑冲压过程中最大剪切角的约束，实施离散优化设计以提高CF/PP试样的弯曲性能。与基准样品相比，优化设计使质量降低了14.3%，比能量吸收（）提高了17.5%。
