A structural composite underbody capable of carrying crash loads has been designed and fabricated by the Automotive Composites Consortium. In Phase 1 of the project, the material and process system was selected as compression molding of sheet molding compound (SMC), with a vinyl ester matrix and predominately glass fabric reinforcement, with some chopped glass. CAE-based design methodologies were utilized to assess the structural stiffness and impact performance of the initial composite underbody design. Phase 2 of the project involved providing a full design of the underbody, including design for durability, and feasible component manufacturing and vehicle assembly scenarios. Weld bonding was selected as the means to join the composite underbody to the steel passenger compartment. A method for weld bonding the structural composite has been developed and tested in static and dynamic modes. Fabric drape of the fabric SMC material was analyzed for the underbody, as well as for some surrogate components. Phase 3 is the fabrication and testing of the targeted underbody. The Automotive Composites Consortium is a joint program between GM, Ford, Chrysler, and the United States Department of Energy.
Design and fabrication of a structural composite automotive underbody
2010
10 Seiten, 12 Bilder, 12 Quellen
Aufsatz (Konferenz)
Englisch
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