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An integrated optimization for laminate design and manufacturing of a CFRP wheel hub based on structural performance

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Abstract

An integrated optimization that comprehensively considers design and manufacturing factors such as the geometric appearance, laminate constitutions, laminate distribution, laminate thickness and stacking sequence, is proposed for designing a carbon fiber reinforced polymer wheel hub of a racecar. First, the driving conditions of the racecar are analyzed to determine the performance requirements. Then, under the condition that the geometric design regions are partitioned and the constitutions of fiber plies with different directions are defined, laminate design and manufacturing model is established. A multi-objective optimization is then performed to achieve a lightweight, high-stiffness laminate structure in different design regions. Next, number of plies in each region is obtained from the thickness of laminate, and then, the stacking sequence is optimized to improve the stiffness of the laminate structure. Finally, laminate transitions for different regions are investigated. The results showed that laminate design and manufacturing optimization can reduce the weight of the wheel hub and improve the performance of the wheel hub under static, dynamic and impact conditions. The proposed optimization approach provides a feasible solution for a performance-based design of composite structures.

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Acknowledgements

We are sincerely grateful to Prof. Xu HAN (Hunan University, Hebei University of Technology, P.R. China) for important suggestions, remarks and insights.

Funding

This work was supported by the National Natural Science Foundation of China (Grant Number 51575171).

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, 2 Lushan South Road, Changsha, 410082, People’s Republic of China

    Fei Lei & Ruibin Qiu

  2. National Engineering Laboratory for Electric Vehicles, School of Mechanical Engineering, Beijing Institute of Technology, No. 5 South Zhongguancun Street, Haidian District, Beijing, 100081, China

    Yingchun Bai

  3. Joint Center for Intelligent New Energy Vehicle, Shanghai, 201804, China

    Chengfeng Yuan

Authors
  1. Fei Lei
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  2. Ruibin Qiu
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  3. Yingchun Bai
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  4. Chengfeng Yuan
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Correspondence to Fei Lei.

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Lei, F., Qiu, R., Bai, Y. et al. An integrated optimization for laminate design and manufacturing of a CFRP wheel hub based on structural performance. Struct Multidisc Optim 57, 2309–2321 (2018). https://doi.org/10.1007/s00158-017-1861-7

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  • DOI: https://doi.org/10.1007/s00158-017-1861-7

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