汽车复合材料中顶横梁轻量化设计

Lightweight design of composite middle crossbeam-roof for car roof

采用碳纤维增强热固性复合材料(Carbon Fiber Reinforced Thermosetting Composite,CFRTC)替代原铝合金材料,对某新能源汽车中顶横梁进行轻量化设计。基于CFRTC的成型特点,将中顶横梁的横截面设计为“M”型,兼顾性能要求和轻量化效果,优化截面尺寸;结合装配关系和成型工艺,确定中顶横梁整体结构,利用HyperWorks软件检验中顶横梁安全性能。在雪压、整车弯曲和整车扭转工况下,将两种材料中顶横梁的仿真结果进行对比,结果表明,CFRTC中顶横梁抗压强度和整车弯曲刚度略优于原铝合金中顶横梁,整车扭转刚度有明显提升,中顶横梁减重45.16%,具有工程应用价值。

Different from the general aluminum alloy middle crossbeam-roof for car roof,Carbon Fiber Reinforced Thermosetting Composite(CFRTC)was used to carry out lightweight design for the middle crossbeam-roof of a new energy vehicle.Based on the molding characteristics of CFRTC,the cross section of the beam was designed as“M”type,so as to take into account the performance requirements and lightweight effect,and optimize the section size.According to the assembly relationship and forming process,the overall structure of the middle crossbeam-roof was determined,and then the HyperWorks Software was used to test the safety of it.Finally,according to the simulation results of two materials beams under snow pressure,bending and torsion of the whole vehicle,it is concluded that the compressive strength and bending stiffness of the middle crossbeam-roof which is made of CFRTC are slightly better than the beam made of aluminum alloy,while the torsional stiffness of the whole vehicle is significantly improved.Meanwhile,the calculation results show that the middle crossbeam-roof made of CFRTC mass is 45.16 percent less than the beam made of aluminum alloy,which is of engineering application value.