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Open AccessArticle

Design of Lightweight CFRP Automotive Part as an Alternative for Steel Part by Thickness and Lay-Up Optimization

1
PNU-IFAM JRC, Pusan National University, 63, Busandaehak-ro, Geumjeong-gu, Busan 46241, Korea
2
Graduate School of Convergence Science, Pusan National University, 63, Busandaehak-ro, Geumjeong-gu, Busan 46241, Korea
3
Department of Mechanical Engineering, Dong-A University, Busan 49315, Korea
4
Aircraft Parts Engineering, International University of Korea, Jinju-si 52833, Korea
5
Precision Manufacturing Systems Division, Pusan National University, 63, Busandaehak-ro, Geumjeong-gu, Busan 46241, Korea
*
Author to whom correspondence should be addressed.
Materials 2019, 12(14), 2309; https://doi.org/10.3390/ma12142309
Received: 17 June 2019 / Revised: 17 July 2019 / Accepted: 18 July 2019 / Published: 19 July 2019
(This article belongs to the Collection Metal Forming: Fundamentals, Simulation and Applications)
Mechanical properties, such as strength and stiffness, of laminated carbon fiber reinforced plastic (CFRP) are generally affected by the lay-up method. However, no precise design rules to replace steel products with CFRP have been established that satisfy these properties. Therefore, this study proposes a set of rules to design automotive parts with equivalent bending stiffness through structural analysis and genetic algorithms (GAs). First, the thickness of the CFRP product was determined by comparing the bending deformation of steel products by structural analysis. To minimize the orthotropic characteristics of CFRP, the quasi-isotropic lay-up method was implemented to determine the thickness. Next, the lay-up angle was determined using GAs. The optimized lay-up angle of the CFRP product with minimum bending deformation was determined by population generation, cross-over, mutation, and fitness evaluation. CFRP B-pillar reinforcement was fabricated using the determined conditions and the bending deformation of the single component was evaluated. Finally, the B-pillar assembled with CFRP reinforcement was investigated by the drop tower test. View Full-Text
Keywords: carbon fiber reinforced plastic (CFRP); structural analysis; genetic algorithms (GAs); optimization; B-pillar; reinforcement; drop tower test carbon fiber reinforced plastic (CFRP); structural analysis; genetic algorithms (GAs); optimization; B-pillar; reinforcement; drop tower test
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MDPI and ACS Style

Lee, J.-M.; Min, B.-J.; Park, J.-H.; Kim, D.-H.; Kim, B.-M.; Ko, D.-C. Design of Lightweight CFRP Automotive Part as an Alternative for Steel Part by Thickness and Lay-Up Optimization. Materials 2019, 12, 2309. https://doi.org/10.3390/ma12142309

AMA Style

Lee J-M, Min B-J, Park J-H, Kim D-H, Kim B-M, Ko D-C. Design of Lightweight CFRP Automotive Part as an Alternative for Steel Part by Thickness and Lay-Up Optimization. Materials. 2019; 12(14):2309. https://doi.org/10.3390/ma12142309

Chicago/Turabian Style

Lee, Jeong-Min; Min, Byeong-Jin; Park, Joon-Hong; Kim, Dong-Hwan; Kim, Byung-Min; Ko, Dae-Cheol. 2019. "Design of Lightweight CFRP Automotive Part as an Alternative for Steel Part by Thickness and Lay-Up Optimization" Materials 12, no. 14: 2309. https://doi.org/10.3390/ma12142309

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