电动车轻量化复合材料车身骨架多尺度分析

doi:10.3901/JME.2016.06.145

机械工程学报 ›› 2016, Vol. 52 ›› Issue (6): 145-152.doi: 10.3901/JME.2016.06.145

电动车轻量化复合材料车身骨架多尺度分析

朱国华, 成艾国, 王振, 雷发桂

湖南大学汽车车身先进设计制造国家重点实验室长沙 410082

出版日期:2016-03-15 发布日期:2016-03-15
作者简介:朱国华,男,1987年出生,博士研究生。主要研究方向为汽车复合材料。E-mail：15902972291@163.com;成艾国(通信作者),男,1972年出生,博士,教授,博士研究生导师。主要研究方向为车身结构设计和优化、材料成形CAE分析、汽车产品的生态、环保、节能技术及应用。E-mail：cheng_aiguo@163.com
基金资助:
中国博士后科学基金资助项目(2014M552132)

Analysis of Lightweight Composite Body Structure for Electrical Vehicle Using the Multiscale Approach

ZHU Guohua, CHENG Aiguo, WANG Zhen, LEI Fagui

State Key Laboratory of Advanced Design and Manufacture for Vehicle Body,Hunan University, Changsha 410082

Online:2016-03-15 Published:2016-03-15

摘要/Abstract

摘要： 复合材料由于其微观结构的非均匀性以及复杂的力学特性,使得其零部件设计难度大大增加。采用多尺度分析的方法,根据T300/Epoxy斜纹机织复合材料细观几何参数,建立其单胞几何模型,引入周期性边界条件对单胞结构进行有限元分析,进而预测复合材料层合板三维弹性性能参数,并通过力学试验证明试验结果和预测结果较为接近;利用LS-Dyna中的MAT_54建立复合材料渐进失效模型,通过三点弯曲试验结果调整模型参数,最终得到的复合材料渐进失效模型仿真结果与试验结果一致;将调整好的复合材料渐进失效模型应用到电动车复合材料车身骨架轻量化设计中,对复合材料骨架进行顶压仿真以及柱碰仿真分析。分析结果表明,复合材料车身骨架设计符合法规要求,与铝合金骨架相比,在重量减轻59%的同时表现出更好的耐撞性能。

关键词: 电动车, 多尺度分析, 轻量化, 碳纤维机织复合材料

Abstract: Design of composite structure appears more challenging compared with metallic counterparts because of its microstructural heterogeneity and sophisticated mechanical property. The crashworthiness of composite body structure is investigated by using multiscale approach. The representative volume elementis established by geometric parameters which are obtained by measuring the microscopic structure of T300/Epoxy. Coupled with the periodical boundary condition, the representative volume element is adopted to predict the 3D elastic properties of laminate composite by the finite element method. And the prediction results coincide with the experimental data well. A progressive failure model of laminate composite is established by using material model MAT_54 of LS-Dyna. The simulation results of three points bending test are in good agreement with experimental results by adjusting the model parameters according to experiment results. This model is applied to crashworthiness analysis of composite body structure for electrical vehicle under the roof crash and side pole impact. The simulation results indicate that the design of composite body structure meets the requirements. Meanwhile, the crashworthiness of body structure has been increased coupled with a 59% saving in the body weight compared to the aluminum body structure.

Key words: carbon woven fabric composites, electrical vehicle, lightweight, multiscale approach

中图分类号:

TB332

朱国华, 成艾国, 王振, 雷发桂. 电动车轻量化复合材料车身骨架多尺度分析[J]. 机械工程学报, 2016, 52(6): 145-152.

ZHU Guohua, CHENG Aiguo, WANG Zhen, LEI Fagui. Analysis of Lightweight Composite Body Structure for Electrical Vehicle Using the Multiscale Approach[J]. Journal of Mechanical Engineering, 2016, 52(6): 145-152.

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电动车轻量化复合材料车身骨架多尺度分析

Analysis of Lightweight Composite Body Structure for Electrical Vehicle Using the Multiscale Approach

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