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Integral versus differential design for high-volume manufacturing of composite structures
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures. Volvo Car Corporation, Sweden .ORCID iD: 0000-0002-1224-3662
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.ORCID iD: 0000-0002-9744-4550
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.ORCID iD: 0000-0002-6616-2964
2015 (English)In: Journal of composite materials, ISSN 0021-9983, E-ISSN 1530-793X, Vol. 49, no 23, 2897-2908 p.Article in journal (Refereed) Published
Abstract [en]

In order to decrease the weight of the automotive body structure and increase the energy efficiency of future cars, attention is now turning towards structural composites, mainly carbon fibre-reinforced plastics. Composites have several advantages such as their excellent weight-specific properties and the possibility to be manufactured in large integral designs for a reduced weight and potentially lower cost. However, carbon fibre composites are expensive and for a cost sensitive industry such as the automotive industry, the challenge lies in creating a favourable business case with a well-balanced trade-off between weight and cost. A method is proposed to visualise the cost and weight advantages of either pursuing an integral design or a differential design, i.e. dividing the structure into a greater number of parts that are later assembled. The method focuses on the impact on cost and weight and considers structures with different part sizes and geometrical complexities. It is shown that, depending on the manufacturing process and series volume, larger and more complex parts may become more cost effective when divided into several, later-joined sub-parts. However, for smaller and/or less complex shapes, an integral design solution is always the best choice.

Place, publisher, year, edition, pages
Sage Publications, 2015. Vol. 49, no 23, 2897-2908 p.
Keyword [en]
Composites, automotive, manufacturing, partition, design
National Category
Composite Science and Engineering
Research subject
Vehicle and Maritime Engineering
Identifiers
URN: urn:nbn:se:kth:diva-145714DOI: 10.1177/0021998314557684ISI: 000360851800007Scopus ID: 2-s2.0-84941136175OAI: oai:DiVA.org:kth-145714DiVA: diva2:719922
Funder
XPRES - Initiative for excellence in production research
Note

QC 20150004

Available from: 2014-05-27 Created: 2014-05-27 Last updated: 2017-12-05Bibliographically approved
In thesis
1. Cost and weight effective composite design of automotive body structures
Open this publication in new window or tab >>Cost and weight effective composite design of automotive body structures
2014 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The automotive industry stands in front of a great challenge, to decrease its impact on the environment. One important part in succeeding with this is to decrease the structural weight of the body structure and by that the fuel consumption or the required battery power. Carbon fibre composites are by many seen as the only real option when traditional engineering materials are running out of potential for further weight reduction. However, the automotive industry lacks experience working with structural composites and the methods for high volume composite manufacturing are immature. The development of a composite automotive body structure, therefore, needs methods to support and guide the conceptual work to improve the financial and technical results.

In this thesis a framework is presented which will provide guidelines for the conceptual phase of the development of an automotive body structure. The framework follows two main paths, one to strive for the ideal material diversity, which also defines an initial partition of the body structure based on the process and material selection. Secondly, a further analysis of the structures are made to evaluate if a more cost and weight efficient solution can be found by a more differential design and by that define the ideal part size.

In the case and parameter studies performed, different carbon fibre composite material systems and processes are compared and evaluated. The results show that high performance material system with continuous fibres becomes both

more cost and performance effective compared to industrialised discontinuous fibre composites. But also that cycle times, sometimes, are less important than a competitive feedstock cost for a manufacturing process. When further

analysing the manufacturing design of the structures it is seen that further partition(s) can become cost effective if the size and complexity is large enough.

 

 

 

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2014. vii, 36 p.
Series
TRITA-AVE, ISSN 1651-7660 ; 2014:12
National Category
Vehicle Engineering
Research subject
Vehicle and Maritime Engineering
Identifiers
urn:nbn:se:kth:diva-145292 (URN)978-91-7595-151-5 (ISBN)
Presentation
2014-06-04, Sal D3, Lindstedtsvägen 5, KTH, Stockholm, 13:00 (English)
Opponent
Supervisors
Funder
Swedish Energy Agency, 35854-1
Note

QC 20140527

Available from: 2014-05-27 Created: 2014-05-15 Last updated: 2014-05-27Bibliographically approved
2. Framework for cost and weight efficient conceptual design of automotive composite body structures
Open this publication in new window or tab >>Framework for cost and weight efficient conceptual design of automotive composite body structures
2016 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The automotive industry is facing a great challenge - reducing the weight of their vehicles. Carbon fibre composites are regarded by many as the only real option as traditional engineering materials are now running out of potential for further weight reduction. In this doctoral thesis a framework is presented which will provide guidelines for the conceptual phase of the development of an automotive composite body structure. The framework is initiated by defining ideal material diversity, as well as initial partition of the body structure based on process and material selection. Then, a further analysis of the structures is made in order to evaluate whether a more cost efficient solution can be found by further dividing the structure. Such a differential design approach is analysed in the third part of the work, studying both the financial and structural effects of such partitioning. In order to increase the understanding of the intimate relationship between design, material and manufacturing process, balancing manufacturing and structural optimization is addressed. Finally, drape simulation tools are used to assess the geometric complexity of composite structures in order to further quantify suitable split lines in cases of differential design approach.

Different carbon fibre composite material systems and processes are compared and evaluated in the work. The results show that a high-performance material system with continuous fibres is both more cost and performance effective as compared to industrialised, discontinuous fibre composites. Further analysis shows the importance of balancing the design for manufacturing and the structural weight optimization of the structures in order to reach a cost and weight effective design. When restricting composite design freedom with manufacturing constraints, the great benefits of structural composites disappear and with this both weight and cost effectiveness.

Place, publisher, year, edition, pages
KTH Royal Institute of Technology, 2016. 52 p.
Series
TRITA-AVE, ISSN 1651-7660 ; 2016:18
Keyword
composites automotive cost weight body structure
National Category
Aerospace Engineering
Research subject
Aerospace Engineering; Fibre and Polymer Science; Transport Science
Identifiers
urn:nbn:se:kth:diva-185213 (URN)978-91-7595-944-3 (ISBN)
Public defence
2016-06-03, Sal E3, Osquars backe 14, KTH-Campus, Stockholm, 10:15 (English)
Opponent
Supervisors
Note

QC 20160418

Available from: 2016-04-18 Created: 2016-04-13 Last updated: 2016-05-16Bibliographically approved

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