New method for lightweight design of hybrid components made of isotropic and anisotropic materials

Abstract For the development of efficient and economical car body structures, high-performance lightweight materials such as continuous fiber-reinforced plastics (C-FRP)—especially in combination with quasi-isotropic materials (f.e. metal) as multi-material components—have gained importance. However, the systematic design of such hybrid components is extremely challenging. In the following work, a newly developed method for the weight- and load-optimized design of hybrid components made of isotropic and anisotropic materials based on physical parameters is presented. With the principal stresses of a reference component a weight-optimized structure between isotropic "base material" and load-dependent reinforcement made of C-FRP is calculated for a new multi-material component. The user specifies the mechanical properties as well as min. and max. material thicknesses for the isotropic material and the C-FRP. With this information the lightest possible material combination of isotropic base material and anisotropic C-FRP is then determined. Using this method, a weight saving of 18–62% could be achieved with flat validation examples while maintaining the same stiffness. Application to the frame of a vehicle door also results in a significant weight saving without compromising stiffness. In summary, this method offers the possibility to identify suitable components for the application of weight- and load-dependent hybrid components and to design them in the early stage of the product development process.