基于Fibersim的碳纤维复合材料油底壳设计

Design of Oil Pan in Carbon Fiber Composite Material Based on Fibersim

在汽车轻量化背景下,对金属油底壳进行碳纤维复合材料轻量化设计。首先从轻量化程度、设计性和安全性三个方面出发确定油底壳构件碳纤维复合材料化的可行性;其次,通过Catia软件对原金属油底壳进行结构简化处理,根据复合材料结构设计的规范,去除相关后期机加工结构。通过等刚度替换原理初步确定碳纤维复合材料油底壳的总体厚度为3 mm。依据结构优化、工艺设计和铺层结构等方面的设计规范,利用Fibersim软件进行油底壳结构的铺层设计,探讨盒类复杂件的铺层裁剪方案。分别对碳纤维复合材料油底壳结构的0°,90°,–45°和45°的铺层进行铺覆可行性分析,对不满足铺覆可行性的铺层分别使用剪口和分块方案并评估,最终依据不合格率和完整度两项指标确定剪口方案为最佳方案。

Under the background of automobile lightweight,the design of oil pan in carbon fiber composite material has been carried out which can also provides some guidance for the design of other parts in composite material.Firstly the feasibility of carbon fiber composites for oil pan components was determined from three aspects:lightweight,design and safety.Then the structure of the original metal oil pan was simplified by Catia software,and the related post machining structure was removed according to the specification of composite structure design.Based on the principle of equal stiffness replacement,the overall thickness of the carbon fiber composite oil pan was determined to be 3 mm.Based on the design specifications of structural optimization,process design and layup structure,Fibersim software was used to design the layup of the oil pan structure and to explore the layup cutting scheme of the complex parts of the box.The feasibility analysis was conducted for the 0°,90°,-45°and 45°plies of the carbon fiber composite oil pan structure,then the cutting and blocking schemes were used respectively for the layering that does not meet the feasibility of the laying,and the cutting scheme was finally determined as the best scheme according to the two indexes of unqualified rate and integritied rate.