Optimization of Multi-area Layup Structure for Composite Control Arm
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摘要: 使用碳纤维复合材料设计某乘用车悬架控制臂，对4个区域的铺层结构进行优化设计。首先以各角度铺层厚度为设计变量对控制臂模态频率、质量和各工况应变能进行优化；然后以前三阶模态频率为目标，弯曲刚度参数作为设计变量优化铺层顺序。针对设计变量间存在的工艺约束条件使样本空间不规则且优化变量较多的问题，利用聚类分析进行试验设计确定训练近似模型需要的样本点，并用高斯过程回归方法建立近似模型以减少计算时间，验证模型R2在0.9以上。两步优化后，对比复合材料初始铺层各性能指标均有不同程度改善，复合材料质量减少11.4%；对比原钢制控制臂，各性能均满足要求，质量降低37.1%。Abstract: The layup structure in 4 areas of the suspension control arm of passenger car by using carbon fiber composite is optimized. Firstly, the layer thickness of each angle was regarded as the designing variable to optimize the modal frequency, quality and strain energy under each working condition of control arm. Then the modal frequency was regarded as the target, and the bending stiffness parameter was used as the designing variable to optimize the layup order. Based on the design of experimental of cluster analysis method, the sample points of the approximate model were determined. The Gaussian process regression method was used to establish the approximate model to save the computation cost, and the value of R2 in verification model was above 0.9. After two-step optimization, the performance indexes of the initial designing plan are improved to some extent and the composite materials are reduced by 11.4%. Comparing with the steel control arm, the mass is reduced by 37.1% to meet all the requirements.
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Key words:
- composite /
- optimization /
- design of experiment /
- approximate model
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表 1 碳纤维复合材料力学性能
材料性能 数值 材料性能 数值 0拉伸模量E1/GPa 138 90°拉伸模量E2/GPa 11 0拉伸强度XT/MPa 1500 90°拉伸强度YT/MPa 27 0压缩强度Xc/MPa 900 90°压缩强度Yc/MPa 200 剪切模量G12 /GPa 5.5 剪切强度S/MPa 80 主泊松比ν12 0.28 次泊松比ν23 0.4 
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表 2 复合材料控制臂初始铺层计算结果
参数 响应 结果 要求 备注 模态频率/Hz 1阶 409.3 >400 满足要求 2阶 496.5 − − 3阶 597.4 − − 单轮升起 应变能/J 0.1231 − − 安全系数 5.435 >1 满足要求 右转向 应变能/J 0.3212 − − 安全系数 3.226 >1 满足要求 前进制动 应变能/J 0.3451 − − 安全系数 4.292 >1 满足要求 后退单后轮制动 应变能/J 0.3790 − − 安全系数 3.559 >1 满足要求 前进单前轮制动 应变能/J 0.1427 − − 安全系数 5.848 >1 满足要求
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表 4 铺层厚度优化结果
mm 区域 0 45° 90° −45° AB 0.4 0.5 1.1 0.4 AC 0.3 0.5 1.1 0.5 BC 0.3 0.7 0.9 0.6 P 0.5 0.3 0.5 0.7
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表 5 铺层厚度优化前后对比
铺层 1阶频
率/Hz单轮升起/J 右转弯/J 前进制动/J 后退单后轮制动/J 前进单前轮制动/J 总应变能/J 复合材料质量/kg 初始 409.3 0.123 0.321 0.345 0.379 0.143 1.311 0.81 优化后 预测值 424.7 − − − − − 1.137 0.72 计算值 427.3 0.101 0.261 0.319 0.375 0.137 1.193 0.72 误差/% 0.06 − − − − − 4.69 0 变化比/% 4.4 −17.9 −18.7 −7.5 −1.1 −4.2 −9.0 −11.4
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表 8 优化后铺层顺序
区域 $\xi^{D}_{1} $ $\xi^{D}_{2} $ $\xi^{D}_{3} $ 铺层结构 AB −0.031 −0.512 0.173 [45/(±45)2/452/−452/(90/0)2/903/0/904/0/ 902]s AC −0.192 −0.600 0.077 [452/−453/453/90/−452/904/(0/903)2/0]s BC −0.003 0.035 0.012 [0/−45/90/0/−45/452/90/0/452/90/−45/902/45/90/−45/90/−45/±45/90/45/90]s P 0.562 0.188 −0.138 [04/45/0/−453/45/(−452/90)2/902/45/90]s
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表 10 SAPH440与复合材料控制臂对比
参数 响应 SAPH440 复合材料 变化比/% 模态频率/Hz 1阶 560.6 437.7 −21.9 2阶 735.1 547.0 −25.5 3阶 814.7 620.1 −23.9 单轮升起 应变能/J 0.977 0.101 3.5 安全系数 4.59 7.69 67.5 右转弯 应变能/J 0.216 0.261 20.5 安全系数 2.78 5.00 79.9 前进制动 应变能/J 1.094 0.319 −70.8 安全系数 1.82 5.88 223.1 后退单后轮制动 应变能/J 1.757 0.375 −78.7 安全系数 1.38 3.13 126.8 前进单前轮制动 应变能/J 0.572 0.137 −76.0 安全系数 2.45 5.26 114.7 质量/kg − 1.97 1.24 −37.1
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