Li, Danshi: Lightweight concept design of economical FRTP-metal multi-material vehicle doors. 2021
Inhalt
- Title page
- Acknowledgement
- Zusammenfassung
- Abstract
- Content
- Abbreviation
- Symbol
- 1 Introduction
- 2 State of the art
- 2.1 Fiber-reinforced thermoplastics for lightweight vehicles
- 2.1.1 Typical categories of FRTP material on lightweight vehicles
- 2.1.2 Typical mass-production-oriented manufacturing methods for FRTPs
- 2.2 Lightweight construction methods for FRP BIW components and applications
- 2.3 Typical construction of vehicle door
- 2.3.1 Door classification based on load-bearing structures
- 2.3.2 Door classification based on window frame structures
- 2.4 Door requirements definition
- 2.5 Existing lightweight studies and applications on vehicle doors
- 2.5.1 Lightweight door with steel
- 2.5.2 Lightweight door with light alloy
- 2.5.3 Lightweight door with fiber reinforced plastic (FRP)
- 2.6 Mass-production-oriented joining techniques for FRTPs and multi-material components
- 2.7 Component development method with limited BIW data
- 2.8 Summary and cognition of the state-of-the-art technology
- 3 Concept, development process, and requirements
- 3.1 The multi-material door concept
- 3.1.1 Preliminary FLB concept (starting point)
- 3.1.2 New concept ideas
- 3.1.3 Material choice and property – LFT and UD Tape
- 3.2 Development goal and process
- 3.3 Summary of general FEA modeling techniques
- 4 Reference door analysis
- 5 Structural development with topology optimization
- 6 Door concept, structural validation, and parameteroptimization
- 6.1 Concept 1
- 6.2 Concept 2
- 6.3 Comparison and evaluation of different door concepts
- 6.4 Rapid prototyping with additive manufacturing
- 7 FRTP-metal multi-material door – opportunity and challenge in mass manufacturing
- 8 Summary and outlook
- 9 Reference
- 10 Appendix
- 10.1 Intrusion and intrusion velocity comparison of component development method
- 10.2 Bill of material of the FLB-concept
- 10.3 Detail of the FE model for the crash simulation
- 10.3.1 Important modeling requirement for the full vehicle crash simulation
- 10.3.2 *Mat_24 in Ls-Dyna with the stain rate dependency
- 10.3.3 Modeling UD-Tape with *Mat_54 in Ls-Dyna
- 10.4 Bill of material of the reference door
- 10.5 Schematics of the door static test bench (CAD)
- 10.6 Maximal intrusion comparison between concept 1 and the reference
- 10.7 Maximal intrusion comparison between concept 2 and the reference
- 10.8 Door material cost calculation and comparison
- 10.9 Life cycle analysis on automotive door outer panel