Optimization approach helps design lighter carbon fiber composites
Approach developed by Tokyo University of Science for manufacturing carbon fibers with optimized orientation and thickness achieves more than a 5% weight reduction in fiber-reinforced materials.
Photo Credit: Stefan Fluck
Researchers from Tokyo University of Science (TUS, Japan) have adopted a new design method that optimizes both carbon fiber thickness and orientation, achieving weight reduction in fiber-reinforced composites and opening doors to lighter aircrafts and automotive vehicles.
TUS points to carbon fiber-reinforced polymers (CFRP) which has been continuously studied to improve strength. Most of these studies, says TUS, have focused on a particular technique called “fiber-steered design,” which optimizes fiber orientation to enhance strength.
However, the fiber-steered design approach is not without its drawbacks. “Fiber-steered design only optimizes orientation and keeps the thickness of the fibers fixed, preventing full use of the mechanical properties of CFRP. A weight reduction approach, which allows optimization of fiber thickness as well, has been rarely considered,” explains Dr. Ryosuke Matsuzaki from TUS, whose research is focused on composite materials.
Against this backdrop, Dr. Matsuzaki — along with his colleagues at TUS, Yuto Mori and Naoya Kumekawa — proposed a new design method for optimizing the fiber orientation and thickness simultaneously depending on the location in the composite structure, which allowed them to reduce the weight of the CFRP compared to that of a constant thickness linear lamination model without compromising its strength. Their findings can be read in a new study published in Composite Structures.
General scheme of simultaneous design of fiber orientation and thickness. Photo Credit: Tokyo University of Science (TUS).
Their method consisted of three steps: the preparatory, iterative and modification processes. In the preparatory process, an initial analysis was performed using the finite element method (FEM) to determine the number of layers, enabling a qualitative weight evaluation by a linear lamination model and a fiber-steered design with a thickness variation model. The iterative process was used to determine the fiber orientation by the principal stress direction and iteratively calculate the thickness using “maximum stress theory.” Finally, the modification process was used to make modifications accounting for manufacturability by first creating a reference “base fiber bundle” in a region requiring strength improvement and then determining the final orientation and thickness by arranging the fiber bundles such that they spread on both sides of the reference bundle.
The method of simultaneous optimization led to a weight reduction greater than 5% while enabling higher load transfer efficiency than that achieved with fiber orientation alone.
The researchers note that they’re excited by these results and look forward to the future implementation of their method for further weight reduction of conventional CFRP parts. “Our design method goes beyond the conventional wisdom of composite design, making for lighter aircraft and automobiles, which can contribute to energy conservation and reduction of CO2 emissions,” observes Dr. Matsuzaki.
Related Content
-
PEEK vs. PEKK vs. PAEK and continuous compression molding
Suppliers of thermoplastics and carbon fiber chime in regarding PEEK vs. PEKK, and now PAEK, as well as in-situ consolidation — the supply chain for thermoplastic tape composites continues to evolve.
-
Plant tour: Joby Aviation, Marina, Calif., U.S.
As the advanced air mobility market begins to take shape, market leader Joby Aviation works to industrialize composites manufacturing for its first-generation, composites-intensive, all-electric air taxi.
-
Infinite Composites: Type V tanks for space, hydrogen, automotive and more
After a decade of proving its linerless, weight-saving composite tanks with NASA and more than 30 aerospace companies, this CryoSphere pioneer is scaling for growth in commercial space and sustainable transportation on Earth.