金属/碳纤维混合材料车身构件压溃性能及耐撞性设计

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振动与冲击 ›› 2025, Vol. 44 ›› Issue (1) : 198-211.

冲击与爆炸

金属/碳纤维混合材料车身构件压溃性能及耐撞性设计

梅轩1，赵众豪1，周冠豪 2，任浩乾1，曹悉奥1，朱国华*1，王振1

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Crushing characteristics and crashworthiness design of metal/CFRP hybrid material vehicle body components

MEI Xuan1, ZHAO Zhonghao1, ZHOU Guanhao2, REN Haoqian1, CAO Xi’ao1, ZHU Guohua*1, WANG Zhen1

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摘要

铝合金/碳纤维混合材料是由低成本、高延展性的铝合金与低密度、高强度的碳纤维增强树脂基复合材料（Carbon fibers reinforced plastics，CFRP）组合而成。将该混合材料应用至车身结构设计中，能够有效应对轻量化、材料成本及碰撞安全带来的多重压力，并能够进一步拓展车身结构设计的思路和空间。本文将单向碳纤维增强复合材料（UD-CFRP）、机织碳纤维增强复合材料（WF-CFRP）与方形铝合金薄壁管组合，制备了一系列不同规格的混合材料薄壁结构，并开展轴向准静态压溃实验，揭示了混合材料薄壁结构的耐撞性能。基于实验结果，分析碳纤维增强方式、铺层数以及组分材料相对位置等因素对混合材料薄壁结构耐撞性能的影响，其中CFRP/AL混合材料薄壁结构展现出优异的压溃吸能特性。此外，通过建立有限元模型将UD/AL混合材料薄壁结构引入汽车前纵梁轻量化设计中。最后，采用多目标离散优化算法对UD/AL混合材料前纵梁的铝合金厚度以及碳纤维铺层角度进行优化设计。优化结果表明，与初始设计方案相比，优化后的UD/AL混合材料前纵梁减重34.26%，且比吸能提高42.05%。

Abstract

The Metal/CFRP hybrid materials combine low density and high strength CFRP (carbon fiber reinforced composite plastics) materials with low cost and high toughness metallic materials, which are capable to overcome the challenges of weight reduction, material cost, crash safety and bring more ideas and space for the body structure design in automotive industry. In this work, unidirectional CFRP (UD-CFRP) and woven CFRP (WF-CFRP) is combined with square aluminum alloy thin-walled tubes to prepare a series of composite thin-walled structures with different configurations. Axial quasi-static crushing tests are carried out to reveal the crashworthiness for all specimens. Based on the test results, the effects of fiber architecture, layer number and relative position of constituent parts on the crashworthiness are analyzed, and the CFRP/AL hybrid tubes shows excellent energy-absorbing characteristics. In addition, several FE models of front longitudinal beam are developed to further explore the lightweight effects of UD/AL hybrid materials in front longitudinal beam design. Finally, the aluminum tubal wall thickness and the CFRP ply orientation of UD/AL hybrid front longitudinal beam are designed by multi-objective discrete optimization method. As a result, the weight of the optimal design reduced by 34.26%, and the specific energy-absorbing (Ws) improved by 42.05%, compared with the initial design.

导出引用

梅轩1, 赵众豪1, 周冠豪 2, 任浩乾1, 曹悉奥1, 朱国华1, 王振1. 金属/碳纤维混合材料车身构件压溃性能及耐撞性设计[J]. 振动与冲击, 2025, 44(1): 198-211

MEI Xuan1, ZHAO Zhonghao1, ZHOU Guanhao2, REN Haoqian1, CAO Xi’ao1, ZHU Guohua1, WANG Zhen1. Crushing characteristics and crashworthiness design of metal/CFRP hybrid material vehicle body components[J]. Journal of Vibration and Shock, 2025, 44(1): 198-211

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