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From aviation to automotive - a study on material selection and its implication on cost and weight efficient structural composite and sandwich designs
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering.ORCID iD: 0000-0001-6729-8604
Volvo Car Corp, Gothenburg, Sweden..
Saab AB, Linkoping, Sweden..
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering.ORCID iD: 0000-0002-6616-2964
2020 (English)In: HELIYON, ISSN 2405-8440, Vol. 6, no 3, article id e03716Article in journal (Refereed) Published
Abstract [en]

The design of a composite material structure is often challenging as it is driven by the trade-off between lightweight performance and production costs. In this paper, the boundaries of this design trade-off and its implications on material selection, geometrical design and manufacturability are analysed for a number of design strategies and composite material systems. The analysis is founded on a methodology that couples weight-optimization and technical cost modelling through an application-bound design cost. Each design strategy is evaluated for three levels of bending and torsional stiffness. The resulting stiffness-versus-cost-range together constructs the design envelope and provides guidelines on the suitability and improvement potential of each case. Design strategies researched include monolithic, u-beam-, sandwich-insert- and sandwich-stiffened plates. Considered material systems include carbon-, glass, recycled carbon-, lignin- and hemp-fibre reinforced composites. Optimized sandwich designs are shown to have lowest design cost. Glass-, recycled carbon-, lignin- and hemp-fibre reinforced composite materials are all shown to reduce costs but at lower stiffness performance. Ultimately, the case study demonstrates the importance of early structural design trade-off studies and material selection and justifies introducing novel fibre systems in low-cost applications of moderate stiffness levels.

Place, publisher, year, edition, pages
Elsevier, 2020. Vol. 6, no 3, article id e03716
Keywords [en]
Aerospace engineering, Mechanical engineering, Composite materials, Computer-aided engineering, Manufacturing engineering, Materials processing, Carbon fibres, Sandwich structures, Natural fibres, Recycled carbon fibres
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:kth:diva-272763DOI: 10.1016/j.heliyon.2020.e03716ISI: 000522422500193PubMedID: 32258506Scopus ID: 2-s2.0-85082553150OAI: oai:DiVA.org:kth-272763DiVA, id: diva2:1427328
Note

QC 20200429

Available from: 2020-04-29 Created: 2020-04-29 Last updated: 2020-04-29Bibliographically approved

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Karlsson Hagnell, MathildaÅkermo, Malin

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