Change search
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • harvard1
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf
Method for cost and weight-efficient material diversity and partitioning of a carbon fibre composite body structure
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: Proceedings of the Institution of mechanical engineers. Part D, journal of automobile engineering, ISSN 0954-4070, E-ISSN 2041-2991Article in journal (Refereed) Published
Abstract [en]

A method for the early concept phase is proposed, which is aimed at limiting the financial and performance-related riskswhen designing a carbon fibre composite automotive body structure. The method manages the structural requirementsimposed on the complete body structure and analyses the suitability of different carbon fibre material systems and pro-cesses. It also studies whether a high level of material diversity is desirable and the way in which to identify the optimalpartition of the body structure from a material system and manufacturing process selection point of view. Furthermore,since composite materials include both laminated materials and quasi-isotropic materials, an approach is presented thatenables the comparison of these materials variants during conceptual material selection. A case study exemplifies themethod and the results show that, in spite of the cost-sensitive nature of the automotive industry, utilization of the max-imum performance of these expensive composite materials is more important than efforts to achieve a rapid manufac-turing process.

Place, publisher, year, edition, pages
Sage Publications, 2015.
Keyword [en]
Concept phase, diversity of automotive material, body structure, material selection, process selection, structural composites
National Category
Composite Science and Engineering
Research subject
Vehicle and Maritime Engineering
Identifiers
URN: urn:nbn:se:kth:diva-145713DOI: 10.1177/0954407015578037ISI: 000367381700004Scopus ID: 2-s2.0-84951936233OAI: oai:DiVA.org:kth-145713DiVA: diva2:719921
Funder
XPRES - Initiative for excellence in production research
Note

QC 20150623

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

Open Access in DiVA

fulltext(1316 kB)120 downloads
File information
File name FULLTEXT01.pdfFile size 1316 kBChecksum SHA-512
2c84d3f6bb8cb3fe908a84ff0f3f967a7dadc2cc198a1dffd743217296a4dda20fb5c4728356baf6dd9d20fabe61379daae47e2fdf148bbfc9050a822b10e1e2
Type fulltextMimetype application/pdf

Other links

Publisher's full textScopus

Authority records BETA

Mårtensson, PerZenkert, DanÅkermo, Malin

Search in DiVA

By author/editor
Mårtensson, PerZenkert, DanÅkermo, Malin
By organisation
Lightweight Structures
In the same journal
Proceedings of the Institution of mechanical engineers. Part D, journal of automobile engineering
Composite Science and Engineering

Search outside of DiVA

GoogleGoogle Scholar
Total: 120 downloads
The number of downloads is the sum of all downloads of full texts. It may include eg previous versions that are now no longer available

doi
urn-nbn

Altmetric score

doi
urn-nbn
Total: 325 hits
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • harvard1
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf