Research On The Lightweight Of CFRP Non-bearing Smart Car Body

Lightweight is one of the development trend of automobile industry,which is of great significance to reduce the energy consumption and increase the driving range.This paper takes the newly developed new energy intelligent car,which is designed for the elderly accompanying and walking,as the research object.The intelligent car which has a design weight of 125 kg and maximum speed is 20km/h,with intelligent functions such as visual recognition,path planning,voice interaction,etc.This requires to design lighter body of the intelligent car,which lower than 45 kg.Therefore,this paper focuses on the lightweight technology of intelligent vehicle body.Based on the CFRP material,the lightweight body of the intelligent car is designed and manufactured,by carrying out a systematic study of material selection analysis,process,simulation analysis and test.The main contents and conclusions of this paper are as follows:1.Aiming at the goal of car body lightweight,based on the analysis of the mechanical properties of CFRP reinforced fiber and base material,and the way of laying-layer,through the mechanical,thermal and insulation performance tests,using the comparative analysis of parameter weight,finally select the intelligent car body CFRP material with the best performance.2.Use Solid Works and Moldflow to build the RTM process simulation model of intelligent car body,which made of CFRP material.And then CAE analysis were carried out for the straight beam,bent beam and windshield of intelligent car body,the influence of gate location,gate number,pouring temperature and pouring pressure on the pouring time of RTM process is analyzed.Based on these analysis,optimal RTM process parameter of CFRP material is obtained.3.Based on the study of CFRP material and RTM process,combined with the development process of modern car body and the theory of car body stiffness,according to the actual stress situation of the car body made of CFRP material,the static stiffness,strength and free mode of the car body under bending and torsion conditions are analyzed by using the FEA method.The body design of intelligent car,which made of CFRP material,is completed,and on this basis,the car body forming practice of CFRP is achieved.4.The prototype of the intelligent car,which the weight is 123.1kg,meet the requirements of lightweight design.The impact strength test,as well as the corrosive and humidity/temperature test were carried out for the body of the intelligent car.And the service life of the designed car body is predicted by using the aging life-time model.