From aviation to automotive - a study on material selection and its implication on cost and weight efficient structural composite and sandwich designs. Issue 3 (March 2020)

• Record Type: Journal Article
• Authors: Hagnell, M.K.; Kumaraswamy, S.; Nyman, T.; Åkermo, M.
• Is Part Of: Heliyon. Volume 6:Issue 3(2020)
• Publication Date: 2020-03
• Subjects: Aerospace engineering -- Mechanical engineering -- Composite materials -- Computer-aided engineering -- Manufacturing engineering -- Materials processing -- Carbon fibres -- Sandwich structures -- Natural fibres -- Recycled carbon fibres; Research -- Periodicals; Medical sciences -- Periodicals; Natural history -- Periodicals; Social sciences -- Periodicals; Earth sciences -- Periodicals; Physical sciences -- Periodicals; 507.2
• DOI: 10.1016/j.heliyon.2020.e03716
• Languages: English
• ISSNs: 2405-8440

Abstract

Abstract: The design of a composite material structure is often challenging as it is driven by the trade-off between lightweight performance and production costs. In this paper, the boundaries of this design trade-off and its implications on material selection, geometrical design and manufacturability are analysed for a number of design strategies and composite material systems. The analysis is founded on a methodology that couples weight-optimization and technical cost modelling through an application-bound design cost. Each design strategy is evaluated for three levels of bending and torsional stiffness. The resulting stiffness-versus cost-range together constructs the design envelope and provides guidelines on the suitability and improvement potential of each case. Design strategies researched include monolithic, u-beam-, sandwich-insert- and sandwich-stiffened plates. Considered material systems include carbon-, glass, recycled carbon-, lignin- and hemp-fibre reinforced composites. Optimized sandwich designs are shown to have lowest design cost. Glass-, recycled carbon-, lignin- and hemp-fibre reinforced composite materials are all shown to reduce costs but at lower stiffness performance. Ultimately, the case study demonstrates the importance of early structural design trade-off studies and material selection and justifies introducing novel fibre systems in low-cost applications of moderate stiffness levels. Abstract : Aerospace engineering; Mechanical engineering; Composite materials; Computer-aided engineering; Manufacturing engineering; Materials processing; Carbon fibres; Sandwich structures; Natural fibres; Recycled carbon fibres