Elaboration of Design and Optimization Methods for a Newly Developed CFRP Sandwich-like Structure Validated by...

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Structural Engineering

Background:

• Increasing demand for lightweight structures with high stiffness, corrosion resistance, and vibration damping in industrial applications.
• Need for advanced materials like Carbon Fiber Reinforced Plastic (CFRP) and Aluminum (Al) in structural design.
• Limitations of existing sandwich and cellular plate structures in meeting stringent performance requirements.

Purpose of the Study:

• To construct a novel lightweight sandwich-like structure combining CFRP face sheets and Aluminum (Al) stiffeners.
• To develop and validate calculation methods for predicting middle deflection and stresses in the new structure.
• To create a mass and cost optimization method for the lightweight structure using Flexible Tolerance optimization.

Main Methods:

• Manufacturing of a CFRP-Al sandwich-like structure for experimental measurements.
• Development of analytical calculation methods for structural deflection and stress analysis.
• Validation of calculation methods through experimental testing and Finite Element Analysis (FEA).
• Implementation of Flexible Tolerance optimization considering seven design constraints (deflection, buckling, stress, eigenfrequency).

Main Results:

• Successful construction of a lightweight CFRP-Al sandwich-like structure.
• Validated calculation methods for predicting structural performance (deflection, stress).
• An effective mass and cost optimization method was developed, prioritizing weight reduction.
• The optimized structure demonstrates significant potential for various industrial applications.

Conclusions:

• The developed lightweight sandwich-like structure offers a promising solution for weight-sensitive applications.
• The elaborated calculation and optimization methods provide valuable tools for designing advanced composite structures.
• The research contributes to the advancement of lightweight structural design in sectors like automotive, aerospace, and construction.