Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile

In order to improve the lightweight level of the automotive floor, reduce material application cost, and improve integrated process manufacturing performance through structural design and optimization, this article proposes a design method to link conceptual design and detailed design and optimize the composite floor by combining free size optimization and size optimization methods. The basic theory of composite mechanics is expounded from the stress-strain theory of single-layer plates, and the stiffness and strength theory of laminated plates, which provides theoretical support for the structural design, material design, and allowable value design of composites. The mechanical properties of CFRP were tested to obtain the basic material parameters of CFRP T300/5208. With the material parameters, the CFRP floor super layers are established in Optistruct software. The shape of the floor super layers is optimized by using the free size optimization method, with the body-in-white (BIW) lightweight coefficient as the objective and the BIW performance as the constraints. The BIW lightweight coefficient is reduced from 4.35 to 4.20 after free size optimization, and the layer blocks shape is obtained and clipped based on engineering application. With the floor mass as the objective and the BIW performance as the constraints, the size optimization of the floor layer blocks thickness is optimized. Then the number of floor layers is obtained, and the CFRP floor is established in Fibersim software. Use the simulation analysis method to compare and verify the performance of the floor before and after optimization. The results show that the failure index of the floor is far less than the failure standard, while the mass of the CFRP floor is reduced by 6.8 kg compared with the original steel floor, which an improvement rate reaching 27.5%. The design and optimization methods presented in this article provide a reference for the design and application of the CFRP floor.