Optimization Design and Mechanical Performance Study of Carbon Fiber-Reinforced Composite Load-Carrying Structures for Subway Driver Cabin

This study systematically investigates the optimization design and mechanical performance of carbon fiber-reinforced polymer (CFRP) load-carrying structures for subway driver cabins to meet the lightweight demands of rail transit. Through experimental testing and micromechanical modeling, the mechanical properties of CFRP and foam core materials were characterized, with predicted elastic constants exhibiting an error of ≤5% compared with experimental data. A shape optimization framework integrating mesh morphing and genetic algorithms achieved a 22% mass reduction while preserving structural performance and maintaining load-carrying requirements. Additionally, a stepwise optimization strategy combining free-size, sizing, and stacking sequence optimization was developed to enhance layup efficiency. The final design reduced the total mass by 29.1% compared with the original model, with all failure factors remaining below critical thresholds across three loading cases. The increased failure factor confirmed that the optimized structure effectively exploited the material’s potential while eliminating redundancy. These findings provide valuable theoretical and technical insights into lightweight CFRP applications in rail transit, demonstrating significant improvements in structural efficiency, safety, and manufacturability.