Abstract

Bumper beam is the key structure to protect the vehicle from impact collision. The aim of this paper is to propose a novel bumper beam consisting of continuous carbon fibre-reinforced plastic (CFRP) bumper beam, which is assembled by carbon fibre-reinforced epoxy (EP/CF) skin panels and carbon fibre-reinforced polycarbonate (PC/CF) corrugated sandwich cores. First, the proposed bumper structure is compression molded and then the crashworthiness performance is evaluated via impact experimental test and numerical analysis. It is demonstrated that the numerical results are in good agreement with the experimental data. Then, the effect of the thickness of panel and core on the intrusion, impact force and specific absorption on the impact performance is investigated by using the sensitivity analysis. Based on this, the Kriging proxy model is adopted for design of experiment (DOE), and a multi-objective optimisation with NSGA-II genetic algorithm is used to optimise the thickness (layers) of the skin panels and sandwich core. Results show that the impact performance meet the requirement of crashworthiness with a mass reduce of 35.57%. Accordingly, the proposed bumper beam exhibit superior impact performance, reduced weight to the traditional integrated counterpart. Furthermore, the structure-material-performance integration is an effective method to design CFRP as structural parts.

摘要

保险杠是保护车辆免受冲击碰撞的关键结构。本文的目的是提出一种由连续碳纤维增强塑料 (CFRP) 保险杠梁组成的新型保险杠梁，该保险杠梁由碳纤维增强环氧树脂 (EP/CF) 蒙皮面板和碳纤维增强聚碳酸酯 (PC) 组装而成/CF) 波纹夹芯。首先，对所提出的保险杠结构进行模压成型，然后通过以下方式评估耐撞性能冲击实验测试和数值分析。表明数值结果与实验数据吻合较好。然后，采用敏感性分析研究面板和芯材厚度对侵入、冲击力和比吸收对冲击性能的影响。在此基础上，采用Kriging代理模型进行实验设计（DOE），采用NSGA-II遗传算法进行多目标优化，优化蒙皮板和夹芯板的厚度（层数）。结果表明，冲击性能满足耐撞性要求，减重35.57%。因此，所提出的保险杠横梁表现出优异的冲击性能，与传统的集成对应物相比重量更轻。此外，