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汽車工業(yè)中的先進復合材料：結(jié)構(gòu)完整性及防撞性（英文版）
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Advanced Composite Materials for Automotive Applications: Structural Integrity and Crashworthiness The automotive industry faces many challenges, including increased global competition, the need for higher-performance vehicles, a reduction in costs and tighter environmental and safety requirements. The materials used in automotive engineering play key roles in overcoming these issues: ultimately lighter materials mean lighter vehicles and lower emissions. Composites are being used increasingly in the automotive industry due to their strength, quality and light weight. Advanced Composite Materials for Automotive Applications: Structural Integrity and Crashworthiness provides a comprehensive explanation of how advanced composite materials, including FRPs, reinforced thermoplastics, carbon-based composites and many others, are designed, processed and utilized in vehicles. It includes technical explanations of composite materials in vehicle design and analysis and covers all phases of composite design, modelling, testing and failure analysis. It also sheds light on the performance of existing materials including carbon composites and future developments in automotive material technology which work towards reducing the weight of the vehicle structure. Key features: Chapters written by world-renowned authors and experts in their own fieldsIncludes detailed case studies and examples covering all aspects of composite materials and their application in the automotive industriesUnique topic integration between the impact, crash, failure, damage, analysis and modelling of compositesPresents the state of the art in composite materials and their application in the automotive industryIntegrates theory and practice in the fields of composite materials and automotive engineeringConsiders energy efficiency and environmental implications Advanced Composite Materials for Automotive Applications: Structural Integrity and Crashworthiness is a comprehensive reference for those working with composite materials in both academia and industry, and is also a useful source of information for those considering using composites in automotive applications in the future. Table of contents : ADVANCED COMPOSITE MATERIALS FOR AUTOMOTIVE APPLICATIONS......Page 3 Contents......Page 7 About the Editor......Page 17 List of Contributors......Page 19 Series Preface......Page 23 Preface......Page 25 Part One FUNDAMENTAL BACKGROUND......Page 27 1.1 Introduction......Page 29 1.2 Polymer Composite Materials......Page 31 1.2.2 Semi-Structural Composites......Page 32 1.2.3 Structural Composites......Page 33 1.2.5 Textile Composites......Page 35 1.3 Application of Composite Materials in the Automotive Industry......Page 38 1.3.1 Crashworthiness......Page 39 1.3.2 Composite Driveshaft and Spring......Page 41 1.3.3 Other Applications......Page 42 1.4 Green Composites for Automotive Applications......Page 43 1.5.1 Modelling the Elastic Properties of Unidirectional Composites......Page 45 1.5.2.1 Analytical Modelling......Page 46 1.5.2.2 Numerical FE Modelling......Page 47 1.6 Discussion......Page 48 1.7 Conclusion......Page 49 References......Page 50 2.1 Introduction - Opportunities for Thermoplastic Composites......Page 55 2.2 Recent Developments in Automotive TPCs......Page 57 2.3.1 Materials Selection: Exploring the Potential of Aligned Fibre TPCs......Page 60 2.3.2 Demonstrator Beam Component......Page 63 2.3.3 TPC Process Development......Page 64 2.3.4 Beam Manufacture......Page 65 2.3.5 Demonstrator Beam Structural Performance......Page 66 2.3.6 Environmental Impact Assessment......Page 70 2.3.7 Economic Analysis......Page 72 2.4 Conclusion......Page 74 References......Page 75 3.1 Introduction......Page 77 3.2 Research Drivers: Energy Efficiency......Page 78 3.3 Lightweight Automotive Materials......Page 79 3.4 Barriers to Carbon Fibre Adoption in the Automotive Industry......Page 81 3.5 Global Production and the Market for Carbon Fibre......Page 84 3.6 Low-Cost Carbon Fibre Programme......Page 86 3.6.2.1 Commodity PAN-Based Precursors......Page 87 3.6.2.2 Lignin-Based Precursors......Page 89 3.6.2.3 Polyolefin-Based Precursors......Page 90 3.6.3.1 Microwave Assisted Plasma Processing......Page 91 3.6.3.2 Advanced Stabilisation/Crosslinking......Page 92 3.6.3.3 Plasma Oxidation......Page 93 3.6.3.4 Advanced Surface Treatment and Sizing......Page 95 3.6.4 Integration: Low-Cost Carbon Fibre Pilot Line......Page 96 References......Page 98 Part Two IMPACT AND CRASH ANALYSIS......Page 101 4.1 Introduction......Page 103 4.2.1 Mechanical Behaviour of Cellular Materials......Page 104 4.2.2 Energy Absorption Capabilities of Cellular Materials......Page 106 4.2.4 Strain Rate Sensitivity of Cellular Materials......Page 107 4.3 Advanced Pore Morphology Foam......Page 109 4.4 Mechanical Properties of Single APM Foam Elements......Page 110 4.5 Behaviour of Composite APM Foam......Page 115 4.5.1 Compressive Loading of Confined APM Foam Elements without Bonding......Page 116 4.5.2 Partially Bonded APM Foam Elements......Page 117 4.5.3 Fully Bonded APM Foam Elements - Syntactic Structure......Page 119 References......Page 122 5.2 Traffic Safety......Page 125 5.3 Alternative Vehicles......Page 127 5.4 Selective Overview of Worldwide Crash Tests......Page 129 5.5.1 Front Crash......Page 132 5.5.2 Side Crash......Page 134 5.6 Composite Materials for Crash Applications......Page 136 5.6.1 Performance Metrics for Energy Absorbing Structures......Page 137 5.6.2 Energy Absorbing Deformation Mechanisms in Composite Profiles......Page 139 5.7 Energy Absorption of Composite Profiles......Page 141 5.7.1 Fibre Material......Page 142 5.7.2 Matrix Material......Page 143 5.7.3 Fibre Volume Fraction......Page 144 5.7.4 Fibre Architecture......Page 145 5.7.6 Geometry......Page 147 5.7.8 Test Direction......Page 148 5.8 Conclusion......Page 150 References......Page 151 6.1 Introduction......Page 155 6.2 Materials for Automotive Applications......Page 158 6.3 Composite and Thermoplastic Materials......Page 159 6.4 Numerical Modelling of Fiat 500 Frontal Transverse Beam......Page 163 6.6 Bumper Beam Thickness Determination......Page 167 6.7 Results and Discussion......Page 168 6.8 Conclusion......Page 171 References......Page 172 7.1 Introduction and Motivation......Page 175 7.2 Conventional Method for the Development of Composite Structures......Page 176 7.3 Approaches to Automotive Lightweight Construction......Page 177 7.4 Requirements for Automotive Structures......Page 180 7.4.2 Load Adapted Design......Page 181 7.4.3 Derivation of Reference Structures......Page 183 7.5 Simulation......Page 184 7.6.1 Overview......Page 186 7.6.2 Prepreg Press Technology: Basic Investigations and Process Parameters......Page 188 7.6.3 Prepreg Press Technology: Bonding of Composite Material and Sheet Metal......Page 189 7.7 Testing......Page 191 7.7.1 Quasi-Static Tests......Page 193 7.7.2 Crash Tests......Page 194 7.8 New Methodology for the Product Engineering of Hybrid Lightweight Structures......Page 196 References......Page 198 8.2.1.1 Constitutive Equations for Composite Materials......Page 201 8.2.1.2 Micro-Mechanics Constitutive Model......Page 202 8.2.1.3 Constitutive Matrices and Stress Update for the Micro-Model......Page 204 8.2.2 Failure Analysis......Page 206 8.2.3.1 Equations in Incremental Form......Page 207 8.2.4 Verification Examples......Page 209 8.3.1.1 Strain Rate Effect on Polymer Resin......Page 214 8.3.1.2 State Variable Modelling Overview......Page 215 8.3.2.1 One-Dimensional Constitutive Equation......Page 217 8.3.2.2 Material Constant Determination......Page 218 8.3.3.2 Modified Equations with Shear Correction Factor......Page 219 8.3.3.3 Three-Dimensional Extension of Internal Stress Evolution Law......Page 220 8.3.4.1 Shell Element Simulation......Page 221 8.3.4.2 Solid Element Simulation......Page 222 8.4 Numerical Results......Page 223 References......Page 229 9.1 Introduction......Page 231 9.2 Composite Structures for Crashworthy Applications......Page 233 9.3 Geometrical and Material Characterisation of the Impact Attenuator......Page 240 9.4 Experimental Test......Page 242 9.5 Finite Element Analysis and LS-DYNA......Page 245 9.6 Comparison between Numerical and Experimental Analysis......Page 246 9.7 Investigation of the Optimal Solution......Page 247 References......Page 250 Part Three DAMAGE AND FAILURE......Page 253 10.1 Introduction......Page 255 10.2 Delamination Failure......Page 256 10.3 Objectives......Page 258 10.4.1 Materials and Laminate Manufacturing......Page 259 10.4.2 Testing Methods......Page 261 10.4.2.1 Mode I Test Method......Page 262 10.4.2.3 Mixed Mode I/II: MMB Test......Page 264 10.4.2.4 Mode II Test Method......Page 265 10.5 Numerical Simulations......Page 266 10.5.1 Virtual Crack Closure Technique......Page 267 10.5.3 Cohesive Zone Model......Page 268 10.7.1 Experimental Results......Page 270 10.7.2 Numerical Results......Page 272 10.7.3 Fractographic Analysis......Page 274 10.7.4 Stress State at the Crack Front......Page 276 References......Page 279 11.1 Introduction......Page 283 11.2.2.1 In-Plane Damage......Page 287 11.2.2.2 Theory of Traditional Cohesive Element for Modelling Delamination......Page 290 11.3.1 Artificial Damping Technique......Page 293 11.3.2 Move-Limit Technique Enforced on Cohesive Zone......Page 294 11.3.3.1 Rate-Independent Adaptive Cohesive Model......Page 297 11.3.3.2 Rate-Dependent Adaptive Cohesive Model......Page 299 11.4.1 DCB Problem......Page 301 11.4.1.1 Standard Numerical Simulations......Page 302 11.4.1.2 Artificial Damping Technique......Page 304 11.4.1.3 Move-Limit Technique......Page 305 11.4.1.4 Rate-Independent ACM......Page 307 11.4.1.5 Rate-Dependent ACM......Page 310 11.4.2 Low-Velocity Impact Problem......Page 312 References......Page 317 12.1 Introduction......Page 319 12.2 Experimental Studies......Page 320 12.3 Mode I Delamination Testing: Double Cantilever Bending Test Analysis and Results......Page 322 12.4 Mode II Delamination Testing: End Notched Flexure Test Analysis and Results......Page 323 12.5 Mixed Mode I/II Delamination Testing: Mixed-Mode Bending Test Analysis and Results......Page 328 12.6 Fracture Failure Envelope......Page 332 12.7 Conclusion......Page 334 References......Page 335 Part Four CASE STUDIES AND DESIGNS......Page 337 13.1.1 Current Landscape......Page 339 13.1.2.2 Electric Vehicle......Page 340 13.1.3 Promise for Lightweight Materials......Page 341 13.1.4 Metal Matrix Composites......Page 342 13.1.5 Cost-Benefit Analysis......Page 344 13.2.1 Solid Ceramic Reinforcements......Page 347 13.2.2 Hollow Reinforcements......Page 349 13.2.3 Carbon Based Materials......Page 352 13.3.2 Cylinder Liner......Page 354 13.3.3 Piston......Page 356 13.3.4 Connecting Rod......Page 357 13.3.5 Main and Other Bearings......Page 358 13.3.6 Crankshaft......Page 360 13.3.8 Engine Accessories......Page 361 13.3.11 Differential Housing......Page 364 13.3.12 Driveshaft......Page 365 13.3.13 Brake......Page 366 13.3.16 Electronics......Page 367 13.4 Conclusion......Page 368 References......Page 369 14.1.1 Lightweight as a Key Technology for Automotive Engineering......Page 371 14.2.1 Structural Durability of Lightweight Wheels Made from FRP......Page 375 14.2.1.1 Requirements on Composite Wheels with Respect to Fatigue......Page 377 14.2.2 Operational Strength Verification of Wheels......Page 378 14.2.3 Evidence of Operational Stability of Car Wheels Made from Plastic......Page 381 14.2.4.1 Fatigue tests on CFRP wheels......Page 382 14.3.1 CFRP Lightweight Wheel with Integrated Electrical Motor - Characteristic Data......Page 384 14.3.2.1 Technical Challenges for Multifunctional Design......Page 385 14.3.2.2 Design of the Wheel......Page 386 14.3.2.3 Manufacturing......Page 388 14.4.2 Qualitative Reliability Analysis of Multifunctional Systems Performed on CFRP Wheel with Integrated Hub Motor under Operation......Page 390 14.4.2.1 Quantitative System Reliability Analysis of Multifunctional Systems Performed on CFRP Wheel with Integrated Hub Motor under Operation......Page 391 14.5 Conclusion......Page 395 References......Page 396 15.2 Composite Materials in Automobile Bodies......Page 397 15.3 Multilayer Composite Materials in Noise and Vibration Treatment......Page 398 15.4.1 Case Study I: Modal Analysis of Vehicle Hood......Page 399 15.4.2.1 Unconstrained Layer Damping Treatment......Page 408 15.4.2.2 Constrained Layer Damping Treatment......Page 409 15.5 Conclusion......Page 412 References......Page 413 16.1 Introduction......Page 415 16.2 Materials Requirements for Brake Rotors......Page 416 16.3 Cast Iron Rotors......Page 418 16.4.1 Carbon-Carbon Composites......Page 419 16.4.2 Ceramic Matrix Carbon Composites......Page 420 16.6 Evaluation of Composite Disc Materials......Page 421 16.7 Surface Engineering of Light Alloy Brake Discs......Page 424 16.8.1 Material Requirements......Page 426 16.8.3 Evaluation of Friction Material Performance......Page 427 16.9 Conclusion......Page 428 References......Page 429 17.1 Current and Proposed Carbon Fibre Applications......Page 431 17.2 Carbon Fibre Polymer Composites: Cost Benefits and Obstacles for Automobiles......Page 433 17.3 Performance Modelling......Page 440 17.3.1 Weight Saving Models......Page 443 17.3.2 Models for Density. Stiffness and Strength......Page 444 17.3.3 Carbon Fibre Sheet Moulding Compounds......Page 448 17.3.4 Performance Modelling Summary......Page 452 17.4.1 Cost of Making Carbon Fibre......Page 453 17.4.2.1 Carbon Fibre Cost Reduction Strategies......Page 454 17.4.2.2 Non-Traditional, Lower Cost Precursor......Page 455 17.4.2.3 Non-Traditional, Lower Cost Conversion Technologies......Page 456 17.4.2.4 Commercialisation of Advanced Technologies......Page 457 References......Page 459 Index......Page 461 |
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