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Xiangfan Fang,Marco Grote 한국자동차공학회 2017 International journal of automotive technology Vol.18 No.5
The main objective of this paper is to introduce a novel method to develop a multi-material body-in-white concept with composite material or hybrid material system. A new method based on the work of Durst (2008) is presented, which works basically in three steps. In the first step, the anisotropy of the components is analyzed to pre-evaluate the potential of FRP-suitable parts. In the second step, the predominating orientation of every finite element is determined and clustered to get a first impression of an appropriate laminate architecture. In the last step, a suitable design with a preliminary stacking sequence is calculated. To prove the feasibility of this method, it has been applied to simple flat coupons and a body-in-white component to show that the method leads to reasonable results.
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Fang Xiangfan,Li Danshi 한국자동차공학회 2023 International journal of automotive technology Vol.24 No.3
The vehicle door, as a major steel-intensive closure, can achieve potential weight savings through the use of lightweight materials and new design principles. The different stiffness and strength requirements in different areas of vehicle doors under static and crash-loading cases mean that multi-material construction using metal and fiber-reinforced plastics can be an effective way to achieve lightweight design with minimal additional cost. Here, a new door structure design concept is introduced, developed, and verified virtually for efficient material utilization. This concept includes a major load-bearing ring structure as a framework and a highly function-integrated inner panel which can also serve as a shear web to carry a minor part of the load. In this concept, every part and all portions of the different materials must contribute to the load-carrying function. Lightweight materials, such as aluminum, long-fiber thermoplastics, and unidirectional tapes, and corresponding massproduction- oriented manufacturing methods are used. Anisotropy analysis under different loadings guarantees an effective local usage of unidirectional tapes. Effective section-wise topology and parameter optimization provide a design suggestion for a rib structure made of long-fiber thermoplastics. The final door concept achieves an approximately 20 % weight reduction and comparable or improved mechanical performance compared to a steel reference door.
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Kloska Tobias,Fang Xiangfan 한국자동차공학회 2021 International journal of automotive technology Vol.22 No.5
In this work, the development of a hybrid lightweight automotive chassis control arm is demonstrated. It includes the development of a new simulation method for designing metal - LFT (long fiber-reinforced thermoplastics) rehybrid parts and the new hybrid forming method for its manufacture. Beginning with the original geometry of a series steel chassis control arm, the design was optimized for the hybrid forming process where a steel sheet part is reinforced by an LFT rib structure, and both parts are joined by an LFT layer. For this purpose, a new FE optimization process chain was established. The thickness of the sheet metal and LFT layers, the geometry and thickness of the ribs of the hybrid control arm could be determined to meet both mechanical and light weight requirements. Afterwards, a suitable tooling concept and process for the hybrid forming were developed and tested. The forming behavior of two different steel grades along with an LFT was demonstrated and analyzed with the help of 3D measurement techniques and relevant section cuts. Finally, a weight reduction of nearly 20 % compared to the original component was realized with the hybrid forming process.
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