![]() ![]() The data from each of the three considered epoxy-resin CFRP composite materials (UD, woven and chopped SMC) add to the publicly available materials characterization database housed at the National Institute of Standards and Technology (NIST). The project results improve the infrastructure for CFRP composite design for automotive structures. Existing capabilities and added scripts enable a seamless integration of manufacturing simulation and component performance analysis. ![]() modeFRONTIER serves as the platform for ICME tool integration and design optimization. These models are incorporated for the first time into a multi-disciplinary optimization workflow for the design of a CFRP composite component. ![]() The new, validated and integrated ICME tools significantly advance the capabilities of the industry and include a novel non-orthogonal material model for preforming analysis, improved compression molding simulations of chopped carbon fiber SMC, industry-first multiscale models of constitutive behavior of chopped SMC, UD and woven continuous fiber composite, refined crash analysis models, and fatigue models. The ICME tools developed in this project meet these design challenges. Strong consideration should also be made of the uncertainty inherent in each process, and the probabilistic nature of materials and manufacturing processes. As the local fiber orientation significantly affects the properties and performance of a CFRP-intensive component, achieving the optimal component design requires tools that are capable of predicting both the microstructure and performance of the component based on fiber architecture, molding process, and curing history. The mechanical properties of CFRP are highly direction-dependent as the initial fabric quality, material layout, preforming and molding processes all determine the final local orientation of the fiber. All three architectures, chopped SMC, UD and woven were investigated in the compression molding manufacturing process. The chopped carbon fiber was investigated in the sheet molding compound (SMC) form. (Moldflow).The project focused on three key architectures of epoxy-resin CFRP composites: chopped carbon fiber, unidirectional (UD) carbon fiber and woven carbon fiber. Researchers from Ford Motor Company led the project team with colleagues from the Dow Chemical Company, Northwestern University, the University of Maryland and partners from the following software companies: Livermore Software Technology Corporation (LS-DYNA), ESTECO (modeFRONTIER), HBM Prenscia (nCode) and Autodesk, Inc. Department of Energy funded the project under award DE-EE0006867 for $6M and industry partners supplied the remaining $2.58M. The four-year project concluded in early FY2019 and leveraged a total budget of $8.58 million dollars. These efforts can help mitigate greenhouse gas emissions from passenger vehicles and have the potential to improve national energy independence. By increasing the accessibility of CFRP component designs, reducing development-to-deployment lead time of CFRP components, and improving the robustness of initial designs, this project supports weight reduction in light-duty vehicles. CFRP composites, with a density of 1.55 g/cm 3 and a tensile strength of up to 2,000 MPa in the fiber direction, have a high strength-to-weight ratio, making them one of the most promising candidates more ยป to replace the metals currently used for automotive structural components. The subframe is a structural automotive component with stringent requirements for vibration, strength, durability and safety performance. This project, Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles, develops Integrated Computational Materials Engineering (ICME) techniques for Carbon Fiber Reinforced Polymer (CFRP) composites and uses these ICME tools within a multi-disciplinary optimization scheme to design a carbon-fiber intensive front subframe for a passenger sedan.
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