基于铺层设计特征的碳纤维增强复合材料悬架控制臂结构优化

Structure optimization of a carbon fiber reinforced composite suspension control arm based on the lay up design features

基于铺层设计特征,提出一种使用碳纤维复合材料对承载结构件进行结构优化设计的方法和流程.该方法综合考虑结构几何特征、材料铺层方式、铺层厚度及铺层角度在设计环节中的序列关系,通过几何设计空间构建、离散变量多目标优化、基于工艺可行性的最优决策等方法实现结构设计.以碳纤维增强复合材料悬架控制臂的轻量化设计为例:首先,以钢质控制臂结构为参考建立复合材料控制臂的几何设计空间;然后,以复合材料铺层便利性为原则对其进行结构设计,采用准各向同性铺层对控制臂的铺层厚度进行设计;进而,以提高控制臂刚度和1阶固有频率为目标,使用优化算法对铺层角度进行多目标优化设计;最后,以工艺可行性为约束对优化结果进行筛选并最终完成结构设计.结果表明,所设计复合材料结构具有更大的刚度和1阶固有频率,并且与钢质结构相比减重47.9%.所提出的方法能够较好地兼顾结构特征和复合材料设计要求之间的关系,为复合材料结构优化设计理论与方法的发展提供有益参考.

Based on the lay up design features,the structure optimization design methods and processes for the bearing structure using carbon fiber reinforced polymer were proposed.This method considered the sequence relationships of the geometry of structure,type of lay up,laminate thickness and stacking angles in the design process.Structural design could be achieved by modeling of the geometric design space,multi-objective optimization of discrete variables and the optimal decision based on the technological feasibility.The lightweight design of carbon fiber reinforced composite suspension control arm was carried out as an example.Firstly,the geometric design space of composite control arm was established on the basis of the steel control arm.Then,the convenience of lay up was treated as the principle during its structural design,and the laminate thickness was designed using the quasi-isotropic plies.Furthermore,in order to improve the stiffness and 1order vibration natural frequency of control arm,the multi-objective optimization of stacking angles was carried out by using optimization algorithm.Finally,the technological feasibility as constraints was used during the filtering of the optimization results and finalized the structure design.Results showed that the designed composite control arm had higher stiffnessand vibration natural frequency while having 47.9%less weight.The proposed method can better take into account the relationship between the structure characteristics and composite design requirements,and provide a useful reference for the development of composite structure optimization design theory and method.