白车身车顶碳纤维复合材料前横梁铺层设计及多层次优化方法

徐立友 ,  徐正中 ,  张帅 ,  王芳瑞

科学技术与工程 ›› 2025, Vol. 25 ›› Issue (29) :12451-12465

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科学技术与工程 ›› 2025, Vol. 25 ›› Issue (29) :12451-12465 DOI: 10.12404/j.issn.1671-1815.2407211
机械、仪表工业

白车身车顶碳纤维复合材料前横梁铺层设计及多层次优化方法

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Laminate Design and Multi-level Optimization Method for Front Crossbeam of Roof Carbon Fiber Composite Material in Body-in-white

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摘要

为了提高汽车车顶前横梁的强度、刚度、轻量化水平,实现材料和结构等方面的平衡,构建碳纤维复合材料前横梁的设计与优化方法,通过提出改进的粒子群优化-细菌觅食优化(particle swarm optimization-bacterial foraging optimization, PSO-BFO)混合算法和铺层多层次优化方法,设计了碳纤维复合材料车顶前横梁。建立白车身有限元模型,并实验验证了模型的准确性,获得优化前的前横梁有限元模型。模拟前横梁在顶压、三点弯曲和压缩工况下的性能,确定铺层优化的边界条件;对T700/WP-R2300材料进行性能测试,为铺层优化提供材料参数;通过自由尺寸优化、尺寸优化确定了碳纤复材前横梁的铺块形状、厚度,结合PSO-BFO混合优化算法优化了铺层顺序。优化后前横梁减重45.47%,顶压、三点弯曲和压缩工况下位移分别降低43.64%、29.58%和28.61%,应力分别降低85%、79.44%和75.03%,验证了多层次优化方法的有效性。

Abstract

To improve the strength, stiffness, and lightweight performance of the automotive roof front crossbeam, achieve a balance in materials and structure, and develop a design and optimization method for the carbon fiber composite front crossbeam, an improved particle swarm optimization-bacterial foraging optimization (PSO-BFO) hybrid algorithm and a multi-level layup optimization method were proposed. The carbon fiber composite roof front crossbeam was then designed using these approaches. A finite element model of the body-in-white was established and experimentally validated for accuracy, resulting in the finite element model of the front crossbeam before optimization. The performance of the front crossbeam under top compression, three-point bending, and compression conditions was simulated to determine the boundary conditions for layup optimization. Performance testing of the T700/WP-R2300 material was conducted to provide material parameters for the layup optimization. Through free-size optimization and size optimization, the shape and thickness of the carbon fiber composite front crossbeam layup were determined, and the layup sequence was optimized using the PSO-BFO hybrid optimization algorithm. After optimization, the weight of the front crossbeam is reduced by 45.47%, and the displacements under top compression, three-point bending, and compression conditions decrease by 43.64%, 29.58%, and 28.61%, respectively. The stresses are reduced by 85%, 79.44%, and 75.03%, respectively, validating the effectiveness of the multi-level optimization method.

关键词

车顶前横梁 / 碳纤维复合材料 / 铺层设计方法 / 多层次优化 / 轻量化

Key words

roof front crossbeam / carbon fiber reinforced composite / layup design method / multi-level optimization / lightweighting

引用本文

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徐立友, 徐正中, 张帅, 王芳瑞. 白车身车顶碳纤维复合材料前横梁铺层设计及多层次优化方法[J]. 科学技术与工程, 2025, 25(29): 12451-12465 DOI:10.12404/j.issn.1671-1815.2407211
XU Li-you, XU Zheng-zhong, ZHANG Shuai, WANG Fang-rui. Laminate Design and Multi-level Optimization Method for Front Crossbeam of Roof Carbon Fiber Composite Material in Body-in-white[J]. Science Technology and Engineering, 2025, 25(29): 12451-12465 DOI:10.12404/j.issn.1671-1815.2407211

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基金资助

工业装备结构分析优化与CAE软件全国重点实验室开放基金项目(GZ2024A03-ZZU)

“科创中原”汽车轻量化产学研协作创新基地项目(2024KCZY315)

河南省“科创中原”青年人才托举项目(2023HYTP012)

河南省重点研发专项(241111241800)

河南省重大科技专项(221100240400)

国家重点研发计划(2022YFD2001203)

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