Browse Publications Technical Papers 2019-01-1122
2019-04-02

Composite Lightweight Automotive Suspension System (CLASS) 2019-01-1122

The Composite Lightweight Automotive Suspension System is a composite rear suspension knuckle/tieblade consisting of UD prepreg (epoxy resin), SMC (vinylester resin) carbon fibre and a steel insert to reduce the weight of the component by 35% and reduce Co2. The compression moulding manufacturing process and CAE optimisation are unique and ground-breaking for this product and are designed to allow high volume manufacture of approx. 30,000 vehicles per year. The manufacturing techniques employed allow for multi-material construction within a five minute cycle time to make the process viable for volume manufacture. The complexities of the design lie in the areas of manufacturing, CAE prediction and highly specialised design methods. It is a well-known fact that the performance of a composite part is primarily determined by the way it is manufactured. The design team were able to use their extensive knowledge of material behaviour and state of the art manufacturing cells to enable a component that meets the required functional requirements. The CAE optimisation techniques developed during the project made a significant contribution to the project by bypassing a traditional approach and also reducing the amount of physical testing required. This was required to understand the failure mechanisms of the sheer number of combinations of fibre orientations that make the predictive analysis methods viable for a topology efficient design. A compression moulding manufacturing technology was developed capable of mass manufacturing the high strength, stiff and complex shaped suspension knuckle. The processing technology is fully automated, achieving a cycle time below 5 minutes.

SAE MOBILUS

Subscribers can view annotate, and download all of SAE's content. Learn More »

Access SAE MOBILUS »

Members save up to 18% off list price.
Login to see discount.
Special Offer: Download multiple Technical Papers each year? TechSelect is a cost-effective subscription option to select and download 12-100 full-text Technical Papers per year. Find more information here.
We also recommend:
TECHNICAL PAPER

Crash and Statics Simulation of Short Fiber Reinforced Polymers in ESI Virtual Performance Solution Taking into Account Manufacturing Effects

2019-01-0715

View Details

TECHNICAL PAPER

Structural Front-End Carrier Using Long Glass Fiber Polypropylene

2002-01-3563

View Details

TECHNICAL PAPER

Modeling Of Adhesively Bonded Joints Using Solid Cohesive Interface Element

2007-01-0984

View Details

X