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Cost and weight efficient partitioning of composite automotive structures
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering. Volvo Car Group, Sweden.ORCID iD: 0000-0002-1224-3662
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering.ORCID iD: 0000-0002-9744-4550
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering.ORCID iD: 0000-0002-6616-2964
2015 (English)In: Polymer Composites, ISSN 0272-8397, E-ISSN 1548-0569Article in journal (Refereed) Published
Abstract [en]

To make carbon fiber composites not only weight but also cost effective in high volume production the different cost drivers need to be addressed and new design philosophies considered. This study analyzes integral and differential design approaches when partitioning large complex composite structures. The influence of different partition philosophies are investigated based on a framework of composites manufacturing cost modelling and structural optimization and the effects are exemplified by a case study. The results show that depending on how the partitioning is made the structural performance and the manufacturing cost is affected. More particularly, if the partitioning is made with the most beneficial philosophy differential designs can improve both these important parameters.

Place, publisher, year, edition, pages
John Wiley & Sons, 2015.
Keyword [en]
Carbon, Carbon fibers, Cost effectiveness, Manufacture, Philosophical aspects, Structural optimization, Automotive structures, Carbon fiber composite, Complex composite structures, Composites manufacturing, Differential designs, High-volume production, Manufacturing cost, Structural performance, Costs
National Category
Vehicle Engineering
URN: urn:nbn:se:kth:diva-177772DOI: 10.1002/pc.23795OAI: diva2:874752
XPRES - Initiative for excellence in production research

QC 20151127

Available from: 2015-11-27 Created: 2015-11-25 Last updated: 2016-04-18Bibliographically approved
In thesis
1. 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.
TRITA-AVE, ISSN 1651-7660 ; 2016:18
composites automotive cost weight body structure
National Category
Aerospace Engineering
Research subject
Aerospace Engineering; Fibre and Polymer Science; Transport Science
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)

QC 20160418

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

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Mårtensson, PerZenkert, DanÅkermo, Malin
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