Reliability optimization design for crashworthiness of Al/CFRP hybrid thin-walled structure

doi:10.3785/j.issn.1006-754X.2022.00.090

Chin J Eng Design

2022, Vol. 29

Issue (6): 720-730 DOI: 10.3785/j.issn.1006-754X.2022.00.090

Optimization Design

Reliability optimization design for crashworthiness of Al/CFRP hybrid thin-walled structure

Zheng-feng ZHANG^1,²(

),Xiao-yu SONG³,Xiao-lei YUAN¹(

),Wen-juan CHEN²,Wei-dong ZHANG⁴

^1.School of Automobile, Chang’an University, Xi’an 710064, China
^2.Shaanxi Automobile Holding Group Co. , Ltd. , Xi’an 710042, China
^3.Chinalco Material Application Research Institute Co. , Ltd. , Beijing 102209, China
^4.Shanghai Jieneng Automobile Technology Co. , Ltd. , Shanghai 201804, China

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Abstract

Lightweight is an important way to make automobile industry develop towards safety, energy conservation and environmental protection. The Al/CFRP (carbon fiber reinforced plastic) hybrid material can improve the lightweight effect while taking into account the material cost and structural crashworthiness. In order to explore the best combination mode of Al/CFRP hybrid thin-walled structure with square cross section, firstly, Al square tubes, CFRP square tubes and Al/CFRP hybrid square tubes were prepared, and quasi-static crushing experiments were carried out. Then, the finite element model that could accurately simulate the crushing response of Al/CFRP hybrid square tube was established. Finally, the multi-objective certainty and reliability optimization design for the Al/CFRP hybrid square tube was carried out by combining experimental design method, agent model technique, multi-objective optimization algorithm and Monte Carlo simulation technology, and the reliability optimization solution with good effect was verified by simulation. The quasi-static crushing experiment results showed that the Al/CFRP hybrid square tube had excellent crashworthiness; the optimization results showed that the constraint reliability of the reliability optimization solution was 10.96% higher than that of the certainty optimization solution, which greatly reduced the failure probability and had stronger practicability. The research results are expected to provide a reference for the optimal design of Al/CFRP hybrid thin-walled energy-absorbing components.

Key words： Al/CFRP (carbon fiber reinforced plastic) hybrid material finite element analysis reliability optimization design

Received: 17 May 2022 Published: 06 January 2023

CLC:

TB 333

Corresponding Authors: Xiao-lei YUAN E-mail: zhangzf1979@yeah.net;yuanxiaolei@chd.edu.cn

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Cite this article:

Zheng-feng ZHANG,Xiao-yu SONG,Xiao-lei YUAN,Wen-juan CHEN,Wei-dong ZHANG. Reliability optimization design for crashworthiness of Al/CFRP hybrid thin-walled structure. Chin J Eng Design, 2022, 29(6): 720-730.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2022.00.090 OR https://www.zjujournals.com/gcsjxb/Y2022/V29/I6/720

Al/CFRP混合薄壁结构耐撞性能可靠性优化设计

轻量化是实现汽车产业向安全、节能、环保发展的一个重要途径。Al/CFRP（carbon fiber reinforced plastic，碳纤维增强复合材料）混合材料能够在提升轻量化效果的同时兼顾材料成本和结构耐撞性能。为探索方形截面Al/CFRP混合薄壁结构的最佳组合方式，首先，制备了Al方管、CFRP方管和Al/CFRP混合方管，并开展准静态压溃实验。然后，建立能够精确模拟Al/CFRP混合方管压溃响应的有限元模型。最后，将试验设计方法、代理模型技术、多目标优化算法和蒙特卡罗模拟技术相结合，对Al/CFRP混合方管分别进行多目标确定性与可靠性优化设计，并对效果较好的可靠性优化解进行仿真验证。准静态压溃实验结果表明，Al/CFRP混合方管具有优异的耐撞性能；优化结果表明，可靠性优化解的约束可靠度相比于确定性优化解提高了10.96%，大大降低了失效概率，具有更强的实用性。研究结果有望对Al/CFRP混合薄壁吸能构件的优化设计提供参考。

关键词： Al/CFRP（碳纤维增强复合材料）混合材料, 有限元分析, 可靠性, 优化设计

Fig.1 Schematic diagram of geometric configuration of Al/CFRP hybird square tube

Table 1 Preparation scheme of each sample

Fig.2 Preparation process of Al/CFRP hybird square tube

Table 2 Final geometric dimension parameters of each sample

Fig.3 Axial quasi-static crushing experimental device

Fig.4 Crushing process and load‒displacement curve of each sample

Fig.5 Implementation flow of CFRP layer failure based on user subroutine (VUMAT) in ABAQUS/Explicit

参数	数值
$t n 0$ /MPa	54
$t s 0$ /MPa	70
$t t 0$ /MPa	70
$G n c$ /MPa	504
$G s c$ /MPa	1 556
$G t c$ /MPa	1 556
$η$	2.284

Table 3 Parameters of CFRP interlaminar failure model

Table 4 AA6061-O aluminum alloy material parameters

Table 5 Elastic parameters and strength parameters of CFRP

参数	数值
G₁₂/MPa	8 400
S₀/MPa	71
$σ ? y 0$ /MPa	115
$r 12$	0.154
C	3 080
a	0.810 6

Table 6 In-plane shear parameters of CFRP

参数	数值
$G f 1 +$	155
$G f 1 -$	255
$G f 2 +$	155
$G f 2 -$	255

Table 7 In-plane damage fracture parameters of CFRP

Fig.6 Finite element model for axial crushing of Al/CFRP hybird square tube

Fig.7 Comparison between simulation and experimental results of axial crushing of Al/CFRP hybrid square tube

Table 8 Comparison between simulation and experimental results of crashworthiness index of Al/CFRP hybrid square tube

Table 9 Experimental design sample points and responses of Al/CFRP hybrid square tube

耐撞性能指标	代理模型构建方法	精度评价指标
耐撞性能指标	代理模型构建方法	$R 2$	R_MSE
F_max	RSM	0.911 8	0.105 6
	Kriging	0.831 4	0.116 7
	RBF	0.753 2	0.249 6
W_s	RSM	0.689 3	0.345 6
	Kriging	0.904 7	0.100 2
	RBF	0.758 3	0.255 2
λ_c	RSM	0.806 5	0.185 6
	Kriging	0.926 3	0.099 8
	RBF	0.796 5	0.213 5

Table 10 Accuracy comparison of agent models for crashworthiness indexes of Al/CFRP hybrid square tube based on different methods

Fig.8 Multi-objective certainty optimization process of Al/CFRP hybrid square tube

Fig.9 Comparison of Pareto frontier optimal solution sets of multi-objective certainty optimization for Al/CFRP hybrid square tube based on different optimization algorithms

Table 11 Optimal solution of multi-objective certainty optimization for Al/CFRP hybrid square tube

Table 12 Initial value and probability distribution of design variables of multi-objective reliability optimization for Al/CFRP hybrid square tube

Fig.10 Multi-objective reliability optimization process of Al/CFRP hybrid square tube based on NSGA-Ⅱ

Fig.11 Comparison of Pareto frontier optimal solution sets of certainty and reliability optimization for Al/CFRP hybrid square tube

Table 13 Comparison of certainty and reliability optimal solutions of Al/CFRP hybrid square tube

Fig.12 Simulation results of Al/CFRP hybrid square tube crushing process based on reliability optimal solution

Fig.13 Simulation results of deformation mode and load‒displacement curve of Al/CFRP hybrid square tube based on reliability optimal solution

Table 14 Comparison of crashworthiness indexes of Al/CFRP hybrid square tube based on agent model and finite element simulation


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