Article(id=1209871353738564022, tenantId=1146029695717560320, journalId=1189621681917173762, issueId=1209871350727046121, articleNumber=null, orderNo=null, doi=10.19620/j.cnki.1000-3703.20230915, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1766385409054, onlineDateStr=2025-12-22, pubDate=1724428800000, pubDateStr=2024-08-24, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1766385409054, onlineIssueDateStr=2025-12-22, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1766385409054, creator=13701087609, updateTime=1766385409054, updator=13701087609, issue=Issue{id=1209871350727046121, tenantId=1146029695717560320, journalId=1189621681917173762, year='2024', volume='', issue='8', pageStart='1', pageEnd='62', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1766385408335, creator=13701087609, updateTime=1766386486799, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1209875874179051590, tenantId=1146029695717560320, journalId=1189621681917173762, issueId=1209871350727046121, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1209875874179051591, tenantId=1146029695717560320, journalId=1189621681917173762, issueId=1209871350727046121, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=53, endPage=62, ext={EN=ArticleExt(id=1209871353977639351, articleId=1209871353738564022, tenantId=1146029695717560320, journalId=1189621681917173762, language=EN, title=Ply Design of Automotive Carbon Fiber Composite Floor Based on PSO-BFO Algorithm, columnId=null, journalTitle=Automobile Technology, columnName=null, runingTitle=null, highlight=null, articleAbstract=

A method for optimizing the layout of carbon fiber composite floorings for BIW was proposed to enhance precision, efficiency, and structural lightweight. Initially, BIW finite element model was established and its efficiency was validated. Subsequently, material parameters for the carbon fiber composite were obtained through mechanical performance testing, followed by conceptual designing and modeling of the flooring layout. Subsequent utilization of continuous variable optimization determined the thickness, block shapes, and layers of the flooring, employing a discretization and rounding strategy to achieve discrete layer numbers for each layup angle. The optimization results show that the Particle Swarm Optimization-Bacteria Foraging Optimization (PSO-BFO) algorithm proposed herein improves flooring quality, static bending stiffness and BIW lightweight coefficient by 34.4%, 6.0% and 5.3%, respectively.

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为提高白车身地板复合材料铺层优化设计的精度、效率及结构轻量化水平,提出了一种碳纤维复合材料地板铺层优化设计方法。首先建立了白车身有限元模型并验证了其有效性,然后通过力学性能测试获取了碳纤维复合材料的参数,并进行了地板铺层的概念设计和建模。接着,采用连续变量优化设计方法确定了地板的铺层厚度、铺块形状和铺层层数,并使用离散化圆整策略获得了各铺向角的离散铺层层数。优化结果表明,所提出的粒子群-细菌觅食混合优化(PSO-BFO)算法对地板质量、静态弯曲刚度和白车身轻量化系数的改善率分别为34.4%、6.0%和5.3%。

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项目 试验结果 仿真结果 相对误差/%
弯曲刚度/N·mm-1 11 717.12 12 412.13 +5.96
扭转刚度/N·m·(°)-1 17 251.95 18 643.31 +8.06
一阶弯曲模态频率/Hz 51.69 52.61 +1.78
一阶扭转模态频率/Hz 32.53 35.62 +9.50
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白车身有限元模型静、动态性能仿真与试验结果对比

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项目 试验结果 仿真结果 相对误差/%
弯曲刚度/N·mm-1 11 717.12 12 412.13 +5.96
扭转刚度/N·m·(°)-1 17 251.95 18 643.31 +8.06
一阶弯曲模态频率/Hz 51.69 52.61 +1.78
一阶扭转模态频率/Hz 32.53 35.62 +9.50
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参数 取值 参数 取值
密度/kg·m-3 1.76×103 拉伸模量/GPa 230
拉伸强度/MPa 3 530 比模量/m²·s-² 130.68×106
比强度/m²·s-² 2.0×106 断裂延伸率/% 1.5
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碳纤维T300的基本性能参数

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参数 取值 参数 取值
密度/kg·m-3 1.76×103 拉伸模量/GPa 230
拉伸强度/MPa 3 530 比模量/m²·s-² 130.68×106
比强度/m²·s-² 2.0×106 断裂延伸率/% 1.5
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参数 取值 参数 取值
弯曲强度/MPa 96.5 拉伸强度/MPa 63.7
弯曲模量/GPa 3.75 拉伸模量/GPa 2.9
弯曲应变/% 2.5 断裂延伸率/% 2.0
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环氧树脂5208的基本性能参数

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参数 取值 参数 取值
弯曲强度/MPa 96.5 拉伸强度/MPa 63.7
弯曲模量/GPa 3.75 拉伸模量/GPa 2.9
弯曲应变/% 2.5 断裂延伸率/% 2.0
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参数 数值 参数 数值
Xt/MPa 1 496 S/MPa 67
Xc/MPa 956 G12/GPa 6.4
Yt/MPa 40 G23/GPa 3.8
Yc/MPa 249 G13/GPa 6.4
E1/GPa 127.6 μ12 0.28
E2/GPa 13.0 μ23 0.30
E3/GPa 10.3 μ13 0.28
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T300/5208复合材料力学性能参数

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参数 数值 参数 数值
Xt/MPa 1 496 S/MPa 67
Xc/MPa 956 G12/GPa 6.4
Yt/MPa 40 G23/GPa 3.8
Yc/MPa 249 G13/GPa 6.4
E1/GPa 127.6 μ12 0.28
E2/GPa 13.0 μ23 0.30
E3/GPa 10.3 μ13 0.28
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性能参数 数值
拉伸强度/MPa 20.5
剪切强度/MPa 17.8
拉伸模量/GPa 1.85
剪切模量/GPa 0.502
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Araldite 2015结构胶粘剂的力学性能

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性能参数 数值
拉伸强度/MPa 20.5
剪切强度/MPa 17.8
拉伸模量/GPa 1.85
剪切模量/GPa 0.502
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前地板模块 中地板模块 后地板模块
铺层
编号
铺层厚度/mm 铺层层数/层 铺层
编号
铺层厚度/mm 铺层层数/层 铺层
编号
铺层厚度/mm 铺层层数/层
1011 0.118 0.94 2011 0.102 0.81 3011 0.104 0.83
1012 0.063 0.50 2012 0.080 0.64 3012 0.068 0.54
1013 0.084 0.67 2013 0.163 1.30 3013 0.087 0.69
1014 0.151 1.21 2014 0.207 1.65 3014 0.093 0.74
1021 0.208 1.66 2021 0.091 0.72 3021 0.209 1.67
1022 0.113 0.90 2022 0.059 0.47 3022 0.110 0.88
1023 0.083 0.66 2023 0.140 1.12 3023 0.067 0.53
1024 0.147 1.18 2024 0.071 0.56 3024 0.046 0.37
1031 0.208 1.66 2031 0.091 0.72 3031 0.209 1.67
1032 0.113 0.90 2032 0.059 0.47 3032 0.110 0.88
1033 0.083 0.66 2033 0.140 1.12 3033 0.067 0.53
1034 0.147 1.18 2034 0.071 0.56 3034 0.046 0.37
1041 0.096 0.77 2041 0.197 1.57 3041 0.096 0.77
1042 0.054 0.43 2042 0.130 1.04 3042 0.130 1.04
1043 0.074 0.59 2043 0.094 0.75 3043 0.091 0.72
1044 0.062 0.49 2044 0.080 0.64 3044 0.064 0.51
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半厚度铺层优化结果

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前地板模块 中地板模块 后地板模块
铺层
编号
铺层厚度/mm 铺层层数/层 铺层
编号
铺层厚度/mm 铺层层数/层 铺层
编号
铺层厚度/mm 铺层层数/层
1011 0.118 0.94 2011 0.102 0.81 3011 0.104 0.83
1012 0.063 0.50 2012 0.080 0.64 3012 0.068 0.54
1013 0.084 0.67 2013 0.163 1.30 3013 0.087 0.69
1014 0.151 1.21 2014 0.207 1.65 3014 0.093 0.74
1021 0.208 1.66 2021 0.091 0.72 3021 0.209 1.67
1022 0.113 0.90 2022 0.059 0.47 3022 0.110 0.88
1023 0.083 0.66 2023 0.140 1.12 3023 0.067 0.53
1024 0.147 1.18 2024 0.071 0.56 3024 0.046 0.37
1031 0.208 1.66 2031 0.091 0.72 3031 0.209 1.67
1032 0.113 0.90 2032 0.059 0.47 3032 0.110 0.88
1033 0.083 0.66 2033 0.140 1.12 3033 0.067 0.53
1034 0.147 1.18 2034 0.071 0.56 3034 0.046 0.37
1041 0.096 0.77 2041 0.197 1.57 3041 0.096 0.77
1042 0.054 0.43 2042 0.130 1.04 3042 0.130 1.04
1043 0.074 0.59 2043 0.094 0.75 3043 0.091 0.72
1044 0.062 0.49 2044 0.080 0.64 3044 0.064 0.51
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前地板模块 中地板模块 后地板模块
铺层编号 连续铺层层数
/层
离散铺层层数
/层
铺层编号 连续铺层层数
/层
离散铺层层数
/层
铺层编号 连续铺层层数
/层
离散铺层层数
/层
1011 0.94 1 2011 0.81 1 3011 0.83 1
1012 0.50 1 2012 0.64 1 3012 0.54 0
1013 0.67 0 2013 1.30 1 3013 0.69 0
1014 1.21 1 2014 1.65 2 3014 0.74 1
1021 1.66 2 2021 0.72 1 3021 1.67 2
1022 0.90 1 2022 0.47 0 3022 0.88 1
1023 0.66 0 2023 1.12 1 3023 0.53 0
1024 1.18 1 2024 0.56 1 3024 0.37 0
1031 1.66 2 2031 0.72 1 3031 1.67 2
1032 0.90 1 2032 0.47 0 3032 0.88 1
1033 0.66 0 2033 1.12 1 3033 0.53 0
1034 1.18 1 2034 0.56 1 3034 0.37 0
1041 0.77 1 2041 1.57 2 3041 0.77 1
1042 0.43 0 2042 1.04 1 3042 1.04 1
1043 0.59 1 2043 0.75 1 3043 0.72 1
1044 0.49 0 2044 0.64 1 3044 0.51 0
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半厚度圆整铺层结果

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前地板模块 中地板模块 后地板模块
铺层编号 连续铺层层数
/层
离散铺层层数
/层
铺层编号 连续铺层层数
/层
离散铺层层数
/层
铺层编号 连续铺层层数
/层
离散铺层层数
/层
1011 0.94 1 2011 0.81 1 3011 0.83 1
1012 0.50 1 2012 0.64 1 3012 0.54 0
1013 0.67 0 2013 1.30 1 3013 0.69 0
1014 1.21 1 2014 1.65 2 3014 0.74 1
1021 1.66 2 2021 0.72 1 3021 1.67 2
1022 0.90 1 2022 0.47 0 3022 0.88 1
1023 0.66 0 2023 1.12 1 3023 0.53 0
1024 1.18 1 2024 0.56 1 3024 0.37 0
1031 1.66 2 2031 0.72 1 3031 1.67 2
1032 0.90 1 2032 0.47 0 3032 0.88 1
1033 0.66 0 2033 1.12 1 3033 0.53 0
1034 1.18 1 2034 0.56 1 3034 0.37 0
1041 0.77 1 2041 1.57 2 3041 0.77 1
1042 0.43 0 2042 1.04 1 3042 1.04 1
1043 0.59 1 2043 0.75 1 3043 0.72 1
1044 0.49 0 2044 0.64 1 3044 0.51 0
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铺层类型 地板编号 连通区域
A B C
全域共享铺层 ABC
ABC
45° 45° 45° ABC
45° 45° 45° ABC
45° 45° 45° ABC
-45° -45° -45° ABC
-45° -45° -45° ABC
-45° -45° -45° ABC
90° 90° 90° ABC
90° 90° 90° ABC
子域共享铺层 AB
90° 90° BC
独立铺层 B
B
45° A
-45° A
90° B
90° B
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半厚度连续纤维铺层结果

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铺层类型 地板编号 连通区域
A B C
全域共享铺层 ABC
ABC
45° 45° 45° ABC
45° 45° 45° ABC
45° 45° 45° ABC
-45° -45° -45° ABC
-45° -45° -45° ABC
-45° -45° -45° ABC
90° 90° 90° ABC
90° 90° 90° ABC
子域共享铺层 AB
90° 90° BC
独立铺层 B
B
45° A
-45° A
90° B
90° B
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铺层编号 地板编号
A B C
1 45° 45° 45°
2 -45° -45° -45°
3
4 45° 45° 45°
5
6
7 45° 45° 45°
8 45°
9
10
11 -45° -45° -45°
12 -45°
13 90° 90° 90°
14 90° 90°
15 90°
16 -45° -45° -45°
17 90° 90° 90°
18 90°
), ArticleFig(id=1209908884781797657, tenantId=1146029695717560320, journalId=1189621681917173762, articleId=1209871353738564022, language=CN, label=表9, caption=

复合材料地板半厚度铺层顺序

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铺层编号 地板编号
A B C
1 45° 45° 45°
2 -45° -45° -45°
3
4 45° 45° 45°
5
6
7 45° 45° 45°
8 45°
9
10
11 -45° -45° -45°
12 -45°
13 90° 90° 90°
14 90° 90°
15 90°
16 -45° -45° -45°
17 90° 90° 90°
18 90°
), ArticleFig(id=1209908884861489435, tenantId=1146029695717560320, journalId=1189621681917173762, articleId=1209871353738564022, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
优化方法 优化技术 优化结果 改善率/%
M/kg BS/N·mm-1 Q M BS Q
单一优化算法 PSO 22.2 13 085.5 4.23 10.3 5.4 2.8
BFO 19.0 12 837.2 4.20 22.9 3.4 3.4
混合优化算法 PSO-BFO 16.2 13 163.6 4.12 34.4 6.0 5.3
PSO-GA 17.9 13 184.8 4.15 27.4 6.2 4.5
), ArticleFig(id=1209908884932792605, tenantId=1146029695717560320, journalId=1189621681917173762, articleId=1209871353738564022, language=CN, label=表10, caption=

不同优化方法的结果对比

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优化方法 优化技术 优化结果 改善率/%
M/kg BS/N·mm-1 Q M BS Q
单一优化算法 PSO 22.2 13 085.5 4.23 10.3 5.4 2.8
BFO 19.0 12 837.2 4.20 22.9 3.4 3.4
混合优化算法 PSO-BFO 16.2 13 163.6 4.12 34.4 6.0 5.3
PSO-GA 17.9 13 184.8 4.15 27.4 6.2 4.5
), ArticleFig(id=1209908886111392031, tenantId=1146029695717560320, journalId=1189621681917173762, articleId=1209871353738564022, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
项目 钢制地板 复合材料地板
地板质量/kg 24.7 16.2
静态弯曲刚度/N·mm-1 12 415.1 13 163.6
静态扭转刚度N·m·(°)-1 18 643.3 19 098.8
一阶弯曲模态频率/Hz 52.6 58.2
一阶扭转模态频率/Hz 35.6 36.7
白车身轻量化系数 4.35 4.12
), ArticleFig(id=1209908886182695201, tenantId=1146029695717560320, journalId=1189621681917173762, articleId=1209871353738564022, language=CN, label=表11, caption=

优化前、后白车身基本性能对比

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项目 钢制地板 复合材料地板
地板质量/kg 24.7 16.2
静态弯曲刚度/N·mm-1 12 415.1 13 163.6
静态扭转刚度N·m·(°)-1 18 643.3 19 098.8
一阶弯曲模态频率/Hz 52.6 58.2
一阶扭转模态频率/Hz 35.6 36.7
白车身轻量化系数 4.35 4.12
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基于粒子群-细菌觅食混合优化算法的汽车碳纤维复合材料地板铺层设计*
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杨海洋 1, 2 , 丁娟 1, 2 , 蔡珂芳 3, 4 , 王军年 3 , 胡爱成 5
汽车技术 | 2024,(8): 53-62
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汽车技术 | 2024, (8): 53-62
基于粒子群-细菌觅食混合优化算法的汽车碳纤维复合材料地板铺层设计*
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杨海洋1, 2, 丁娟1, 2, 蔡珂芳3, 4, 王军年3, 胡爱成5
作者信息
  • 1 嘉兴南湖学院,嘉兴 314001
  • 2 嘉兴市智能计算与数据科学重点实验室,嘉兴 314001
  • 3 吉林大学,汽车仿真与控制国家重点实验室,长春 130022
  • 4 零束科技有限公司,上海 201800
  • 5 戴姆勒大中华区投资有限公司上海分公司,上海 200080
Ply Design of Automotive Carbon Fiber Composite Floor Based on PSO-BFO Algorithm
Haiyang Yang1, 2, Juan Ding1, 2, Kefang Cai3, 4, Junnian Wang3, Aicheng Hu5
Affiliations
  • 1 Jiaxing Nanhu University, Jiaxing 314001
  • 2 Jiaxing Key Laboratory of Intelligent Computation and Data Science, Jiaxing 314001
  • 3 State Key Laboratory of Automotive Simulation and Control, Jilin University, Changchun 130022
  • 4 Z-One Technology Co., Ltd., Shanghai 201800
  • 5 Daimler Greater China Ltd. Shanghai Branch, Shanghai 200080
出版时间: 2024-08-24 doi: 10.19620/j.cnki.1000-3703.20230915
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为提高白车身地板复合材料铺层优化设计的精度、效率及结构轻量化水平,提出了一种碳纤维复合材料地板铺层优化设计方法。首先建立了白车身有限元模型并验证了其有效性,然后通过力学性能测试获取了碳纤维复合材料的参数,并进行了地板铺层的概念设计和建模。接着,采用连续变量优化设计方法确定了地板的铺层厚度、铺块形状和铺层层数,并使用离散化圆整策略获得了各铺向角的离散铺层层数。优化结果表明,所提出的粒子群-细菌觅食混合优化(PSO-BFO)算法对地板质量、静态弯曲刚度和白车身轻量化系数的改善率分别为34.4%、6.0%和5.3%。

复合材料地板  /  铺层设计方法  /  粒子群-细菌觅食混合优化方法  /  多目标优化

A method for optimizing the layout of carbon fiber composite floorings for BIW was proposed to enhance precision, efficiency, and structural lightweight. Initially, BIW finite element model was established and its efficiency was validated. Subsequently, material parameters for the carbon fiber composite were obtained through mechanical performance testing, followed by conceptual designing and modeling of the flooring layout. Subsequent utilization of continuous variable optimization determined the thickness, block shapes, and layers of the flooring, employing a discretization and rounding strategy to achieve discrete layer numbers for each layup angle. The optimization results show that the Particle Swarm Optimization-Bacteria Foraging Optimization (PSO-BFO) algorithm proposed herein improves flooring quality, static bending stiffness and BIW lightweight coefficient by 34.4%, 6.0% and 5.3%, respectively.

Composite floor  /  Composite ply design method  /  Particle Swarm Optimization- Bacteria Foraging Optimization (PSO-BFO) algorithm  /  Multi-objective optimization
杨海洋, 丁娟, 蔡珂芳, 王军年, 胡爱成. 基于粒子群-细菌觅食混合优化算法的汽车碳纤维复合材料地板铺层设计*. 汽车技术, 2024 , (8) : 53 -62 . DOI: 10.19620/j.cnki.1000-3703.20230915
Haiyang Yang, Juan Ding, Kefang Cai, Junnian Wang, Aicheng Hu. Ply Design of Automotive Carbon Fiber Composite Floor Based on PSO-BFO Algorithm[J]. Automobile Technology, 2024 , (8) : 53 -62 . DOI: 10.19620/j.cnki.1000-3703.20230915
轻量化是汽车工业节能减排最直接、最有效的手段[1]。研究表明,汽车运动中油耗的75%与整车质量有关,乘用车质量每减轻10%,可节约能耗6%~8%,有害气体排放也可减少4%~6%[2-4]。白车身地板不仅是重要的承载部件,而且受到来自路面的多向冲击,其性能关系到整车的NVH、操纵稳定性、可靠性等性能,且对整车碰撞安全性有着重要影响[5]。碳纤维复合材料作为车身最常用的轻量化材料,与铝合金和钢相比可分别实现25%~30%和40%~60%的轻量化效果,优异的力学性能使其成为优良的汽车零部件材料[6-8]。碳纤维复合材料地板不仅具有承受拉、压、弯、剪等综合载荷的高强度和高刚度性能,还具备优良的抗路面冲击和抗撞性能,在轻量化设计方面具有巨大潜力。
粒子群优化(Particle Swarm Optimization,PSO)算法是一种全局优化算法,简单的实现方式和强大的优化能力使其在各种工程设计中得以广泛应用,但其在优化设计过程中存在收敛慢、精度低、易陷入局部极值的倾向[9-11]。为了增强算法的优化能力,实现全局最优,改进的PSO算法被应用于车辆轻量化设计和耐撞性设计[12-14]。细菌觅食优化(Bacteria Foraging Optimization,BFO)算法是一种基于大肠杆菌社会觅食行为的优化算法[15]。然而,与其他成功的自然启发算法相比,原始BFO算法在复杂优化问题上的收敛性差,为了提高性能,大量变体算法应用于不同领域[16-19]
本文首先建立白车身有限元模型,并利用弯曲刚度、扭转刚度和模态试验验证模型的有效性和有限元仿真分析的正确性。然后,对碳纤维复合材料地板进行铺层概念设计和建模,借鉴旅行商问题的解决方案,提出PSO-BFO算法对碳纤维复合材料地板铺层顺序进行多目标优化设计,并利用地板的失效指数和应力分布验证最优铺层顺序方案的可行性。
选取某款A级轿车为研究对象,对白车身模型进行网格划分,建立白车身的弯曲刚度试验、扭转刚度试验和模态测试分析有限元模型。所建立的白车身有限元模型共有450 054个单元、496 228个节点,如图1所示,经检查,网格质量满足仿真分析要求。图2图3所示分别为白车身弯曲与扭转刚度试验和仿真测试工况,图4所示为白车身低阶模态试验工况。表1所示为白车身有限元模型静、动态性能仿真与试验对比结果。由表1可知,白车身有限元模型与实际白车身的刚度和模态频率最大相对误差均小于10%,满足精度要求,能够代替实际白车身进行多目标优化分析。
本文复合材料层合板的强度理论选取蔡-吴(Tsai-Wu)能量多项式强度准则[20]
F i σ i + F i j σ i σ j + F i j k σ i σ j F i j σ i σ k + = 1
式中:FiFijFijk分别为材料i向、ij面内和空间强度性能参数,σiσjσk分别为材料i向、j向、k向应力分量。
在工程应用中通常只取前2项:
F i σ i + F i j σ i σ j = 1     i , j = 1,2 , 3,4 , 5,6
针对二维平面应力,式(2)可推导为:
F 11 σ 1 2 + 2 F 12 σ 1 σ 2 + F 22 σ 2 2 + F 66 σ 6 2 + F 1 σ 1 + F 2 σ 2 = 1
其中,各强度参数为:
F 1 = 1 X t - 1 X c ,   F 11 = 1 X t X c F 2 = 1 Y t - 1 Y c ,   F 22 = 1 Y t Y c F 66 = 1 S 2 ,   F 12 = 1 2 σ 0 2 1 - 1 X t - 1 X c + 1 Y t - 1 Y c σ 0 -                                       1 X t X c + 1 Y t Y c σ 0 2
式中:XtXc分别为材料在拉伸和压缩状态下沿纤维方向的强度;YtYc分别为垂直于纤维方向的拉伸和压缩强度;S为材料的剪切强度;σ0为参考应力,用于对不同材料的强度参数进行标准化。
上述失效准则判定材料遭到破坏的标准是复合材料任一铺层的最大应力或应变高于材料的许用值。即失效准则是建立在复合材料的许用应力和许用应变的基础上,通过对铺层和基体进行计算得到材料的失效指数(式(1)左侧的表达式)。失效指数小于1时,应力或应变在许可范围内;失效指数大于1时,则应力或应变超出了许可范围。但实际上,复合材料某一铺层结构被破坏并不能说明其他铺层也遭到破坏,复合材料仍具有承载能力。
复合材料地板应能够抵抗拉、压、弯、剪等综合载荷,还要具备一定的强度和刚度。通过对比多种典型复合材料的原材料,发现碳纤维T300和环氧树脂5208具有良好的结合性和性能参数,有利于改善复合材料的界面性能,因此本文选取碳纤维T300作为纤维增强体材料、环氧树脂5208作为基体材料,二者的基本性能参数分别如表2表3所示。
通过对碳纤维环氧树脂复合材料T300/5208进行力学性能测试(0°和90°铺层单轴拉伸试验),得到力学性能参数如表4所示,其中,E1E2E3为材料主方向1、2、3上的弹性模量,G12G23G13为材料的面内剪切模量,μ12μ23μ13为面内的泊松比。
本文选取Araldite 2015结构胶粘剂对碳纤维复合材料结构与金属材料结构进行装配连接,采用电子万能试验机研究Araldite 2015结构胶粘剂的对接拉伸和单搭接剪切力学性能,经过多组拉伸和剪切试验,得到相应的力学性能参数如表5所示,可以用于后续的优化设计计算。
本文在Fibersim软件中对碳纤维复合材料地板进行建模,在HyperMesh中进行有限元分析前处理,使用OptiStruct软件对碳纤维复合材料地板铺层进行概念设计和优化。
采用具有较大强度与刚度的复合材料地板,可以在进行结构设计时简化部分加强筋,能够进行一体化设计。同时,在复合材料地板铺层设计过程中忽略结构孔的作用,在完成样件制备后根据安装位置对其进行开孔处理,以保证铺层纤维的连续性和树脂基体流动的连贯性。另外,对复合材料地板的连接翻边进行扩展以增加翻边的面积,提升连接强度、降低连接应力,增强复合材料地板与金属结构之间的连接。碳纤维复合材料地板结构一体化设计如图5所示。
复合材料地板主要以层合板的形式存在,在结构铺层设计阶段,以层合板内的每个单元网格为基本单位,在OptiStruct软件中通过自由尺寸优化对各单元的铺向角、厚度进行优化设计。为简化初始设计变量,将具有相同铺向角的铺层视为一个集合,称为超级层。
复合材料地板结构铺层设计中,以超级层厚度为设计变量,以白车身轻量化系数为优化目标,以白车身的弯曲刚度、一阶弯曲频率和一阶扭转频率为性能约束条件,以各铺层关于中性面对称和每种铺向角所占铺层比例不得低于10%为制造工艺约束条件,构建优化数学模型:
f i n d   T = T 1 , T 2 , , T n m i n   f T = Q s . t .   B S T B S 0   ;   B F T B F 0   ;   T F T T F 0   ;                 C T T 1   ;   C T T 2
式中:f(T)为目标函数,T为铺层块的厚度变量集合,Ti为第i层铺层块的厚度,Q为轻量化系数,BSTBFTTFT分别为白车身弯曲刚度、一阶弯曲频率和一阶扭转频率,BS0BF0TF0分别为BSTBFTTFT的初始值,CT1CT2为工艺约束、铺层顺序约束。
优化过程中,为保证超级层有足够的设计余量,将各超级层初始厚度设置为0.4 mm。提交OptiStruct软件进行计算,经35次迭代后,白车身的轻量化系数由4.35降低至4.20,如图6所示,优化得到的各超级层最优厚度分布情况如图7所示。
以层合板制造厚度为基本单位,可以将每个超级层解析为4组具有不同形状的铺层块。以45°超级层为例,所对应的铺块形状如图8所示。由超级层最优厚度分布情况可知,每个地板模块均对应4个超级层,因此每个地板模块可以解析出16种不同形状的铺层块,其中45°与-45°超级层受均衡对称约束的限制,铺层块形状相同。
以编号范围1011~3044定义所解析出的铺层块。其中:前、中、后地板3个设计域分别编号为1、2、3,以第1位数字编号表示;0°、45°、-45°和90°超级层对应第2位和第3位数字编号,取值范围为01~04;第4位数字编号取值1~4表示每个超级层解析出的铺块形状。
为了方便工业铺层下料裁剪,需要对优化后的铺层块进行规则化处理。前地板模块45°超级层裁剪前、后的铺块形状对比如图9所示。
为了获得每个铺层块的具体铺层层数,设计变量设置为铺层块的厚度,优化目标设置为地板质量,性能约束条件设置为白车身弯曲刚度、扭转刚度和低阶模态频率,引入蔡-吴失效准则(Tsai-Wu Failure Criterion)进行半厚度铺层层数设计,构建的优化数学模型为:
f i n d   T i = T i 1 , T i 2 , , T i n m i n   f T i = M s . t .   B S T i B S 0   ; T S T i T S 0   ;                 B F T i B F 0   ;   T F T i T F 0   ;                 T s a i - W u  
式中:f(Ti)为目标函数,M为地板质量,BS(Ti)、TS(Ti)、BF(Ti)、TF(Ti)分别为白车身优化前弯曲刚度、扭转刚度、一阶弯曲频率和一阶扭转频率,(Ti1,Ti2,…,Tin)中不同排列顺序为设计变量。
通过优化求解可以获得各铺层块的最优铺层厚度Ti,以0.125 mm厚度的单层板为制造单位,计算碳纤维复合材料地板半厚度铺层中每个铺层块的具体铺层层数Ni

Ni=Ti/0.125

受对称均衡性约束的影响,地板铺层均衡对称,故每种铺层块的实际铺层数为2Ni表6所示为碳纤维复合材料地板的半厚度铺层结果,前地板模块共计14.40×2个单向铺层、中地板模块共计14.14×2个单向铺层、后地板模块共计12.74×2个单向铺层。
复合材料地板的前、中、后模块通过复合材料建模软件Fibersim进行分区域铺层建模。初始铺层经过对表6中各地板模块的具体铺层层数进行四舍五入取整而得到。对前、中、后地板模块进行结构铺层建模,为后续的铺层顺序优化提供模型支持。复合材料地板的初始铺层设计如图10所示。
PSO算法虽然具有较高的收敛精度和计算效率,但容易出现早熟收敛现象,在后期缺乏跳出局部最优解的有效机制,进而难以获得全局最优解。本文提出一种将PSO与BFO相结合的混合算法,以平衡局部搜索和全局搜索能力,避免出现早熟收敛现象,并提高收敛精度和收敛效率。
在PSO-BFO算法中,PSO为菌群提供位置、局部最佳位置和全局最佳位置,BFO根据消除、扩散、翻滚和游动等操作来搜索最优解。进行优化时,粒子的状态通过粒子位置Xi的适应值fit(Xi)进行监控,当粒子群的全局极值适应度fg和粒子的个体极值平均适应度favg的比值接近1时,认为粒子群出现停滞现象,立即引入BFO的趋势化操作机制。fgfavg和PSO-BFO算法相应的速度更新公式分别为:

fg=fit(Gbest)

f a v g = i = 1 n f i t P b e s t i n
V i , k + 1 = w V i , k + b 1 h 1 P i , k - P i , q , η , l + b 2 h 2 G k - P i , q , η , l        
式中:Gbest为粒子群体所发现最优位置,即全局最优解;Pbesti为第i个粒子所发现的最优位置,即局部最优解;Gk为粒子群体k代搜索后的位置;n为求解空间维数;Vi,kPi,k分别为k时刻粒子i的速度和位置;w为惯性权重;b1b2分别为加速因子,在(0,2)范围内取值;h1h2分别为两个(0,1)范围内的相互独立的随机函数;P(i,q,η,l)为细菌i在第q次趋势化、第η次繁殖、第l次分裂淘汰后的位置。
PSO-BFO算法的优化流程如图11所示,其中esp为收敛容差,D为迭代步数,Dmax为最大迭代步数。
采用向下圆整的策略对各铺向角连续铺层厚度进行离散化处理得到碳纤维复合材料地板中各铺向角的离散铺层层数。但通过向下圆整策略进行离散化处理会导致层合板刚度减小,结构的承载能力降低。通过对层合板进行添层补偿可以保证结构的承载能力,但要尽可能减少添层数量,以满足轻量化需求。
由于本文采用0°、45°、-45°和90° 4种铺向角进行铺层设计,因此,向下圆整策略所造成的丢层数最多为4层。其中,0°和90°铺向角的添层数量组合情况分别为0、1、2、3、4,45°和-45°铺向角的铺层数由于对称均衡约束而成对出现,因此±45°的添层数量组合情况为0、1、2。连续变量离散化圆整策略的流程如图12所示,其中,KbIKtIFbIFtI分别为白车身弯曲刚度、扭转刚度、一阶弯曲频率、一阶扭转频率的初始值,NI为原始铺层层数,N为向下圆整后的铺层层数,KbKtFbFt分别为添层后的白车身弯曲刚度、扭转刚度、一阶弯曲频率、一阶扭转频率的计算值。
表6中的半厚度铺层优化结果作为离散化圆整铺层的数据基础,利用连续变量离散化圆整策略对复合材料地板进行离散化处理。表7所示为经过离散化圆整处理后获得的半厚度圆整铺层结果,其中前、中、后地板模块分别具有13×2、16×2、11×2个单向铺层。
变厚度复合材料地板进行独立铺层设计时会导致各模块间的过渡区域无连续铺层纤维过渡,出现丢层现象,因此需要通过连续纤维铺层策略在前、中、后地板模块之间尽可能创建共享铺层,减少丢层现象带来的缺陷。
为了便于描述,定义Adθ、Beθ、Cfθ、(ABC)iθ、(AB)jθ、(BC)kθ,其中:θ为铺向角;defijk对应θ铺向角的铺层层数;A、B、C对应前、中、后地板模块;(ABC)表示全域共享铺层,是3个相邻模块构成的整体区块;(AB)、(BC)分别表示区块A与B的连通区块、区块B与C的连通区块,为子域共享铺层。
表7中前、中、后地板对应的A、B、C 3个相邻铺层模块表示为:
  A = A 3 0 + B 4 ± 45 + C 2 90   B = A 5 0 + B 3 ± 45 + C 5 90   C = A 2 0 + B 3 ± 45 + C 3 90
使用连续纤维铺层策略对式(11)进行处理,可得:
A B C 2 0 + A B 1 0 + B 2 0 A B C 3 ± 45 + A 1 ± 45 A B C 2 90 + B C 1 90 + B 2 90
由式(12)可知,0°、±45°和90°的全域共享铺层的层数分别为2层、3层和2层,子域共享铺层A、B区块共享和B、C区块共享的铺层数均为1层,独立区块A和B均有剩余独立铺层,区块C无剩余独立铺层。
表8所示为碳纤维复合材料地板半厚度连续纤维铺层结果:复合材料地板共有36个铺层,其中全域共享铺层20个,包括4个0°全域共享铺层、6个45°全域共享铺层、6个-45°全域共享铺层、4个90°全域共享铺层;子域共享铺层和独立铺层数量分别为4个和12个。
在铺层顺序优化设计过程中,为了能够在保证白车身静态与动态性能的同时,较好地通过设定优化目标对地板进行轻量化设计,构建优化数学模型:
f i n d     X i = x i 1 , x i 2 , , x i n m i n   f X i = Q X i , - B S X i s . t .   B F X i B F 0                 T F X i T F 0                 C T 1 ,   C T 2 ,   C T 3
式中:xi1,xi2,…,xin为设计变量,Q(Xi)为轻量化系数,BS(Xi)为车身弯曲刚度,BF(Xi)、TF(Xi)分别为白车身一阶弯曲和扭转频率,CT3为连续铺层约束。
以工程约束为指导,对表8中的10个全域共享铺层进行铺层顺序优化,获得全域共享铺层所对应的铺层顺序解集,然后将表8中的子域共享铺层和独立铺层按照面积由大到小的顺序依次插入全域共享铺层中,其中子域共享铺层由表面向中面插入,独立铺层由中面向表面插入。出现某一模块不满足工程约束时,通过添加合适的铺层调整,不断迭代寻优,得到复合材料地板半厚度铺层排序结果如表9所示。
为了验证所提出混合优化方法的有效性,在相同条件下,分别采用单一优化算法和混合优化算法对地板铺层顺序进行优化设计。表10所示为使用不同优化方法的对比结果,由表10可知,不同的优化方法均可以在一定程度上改善白车身的性能并减轻地板质量,但使用单一优化算法容易陷入局部最优解。相比之下,混合优化算法能够获得更加完善的结果,所提出的PSO-BFO方法对地板质量M、静态弯曲刚度BS和白车身轻量化系数Q的改善率分别为34.4%、6.0%和5.3%,粒子群优化-遗传算法(Particle Swarm Optimization-Genetic Algorithm,PSO-GA)对MBSQ的改善率分别为27.4%、6.2%和4.5%。虽然PSO-BFO方法和PSO-GA方法都可以获得复杂优化问题的全局最优解,但PSO-BFO方法较PSO-GA方法得到的结果更为均衡。因此,所提出的PSO-BFO方法能够有效解决复合材料地板铺层顺序的多目标优化问题。
碳纤维复合材料地板比原钢制地板质量减轻8.5 kg,改善率达到了34.4%。为了验证所获得的碳纤维复合材料地板最优解的有效性,对表9中的最优铺层顺序方案进行性能校核验证,图13所示为复合材料地板在弯曲和扭转工况下的失效指数分布情况,其最大失效指数分别为0.109和0.035,远小于失效标准1。图14所示为复合材料地板在弯曲和扭转工况下的应力分布云图,其最大应力分别为33.8 MPa和19.5 MPa,均小于复合材料横向拉伸强度40 MPa。因此,设计的复合材料地板能够在轻量化的同时较好地满足强度和刚度需求,具有良好的疲劳可靠性。
表11所示为优化前、后白车身的具体性能对比,白车身轻量化系数改善率达5.3%。同时,白车身的静态与动态性能显著改善,静态弯曲刚度和静态扭转刚度分别提高了6.0%和2.4%,一阶弯曲模态频率和一阶扭转模态频率分别提高了10.6%和3.1%。
本文以某乘用车白车身为基础研究对象,建立白车身有限元模型,通过试验测试了碳纤维复合材料的力学性能,确定了复合材料T300/5208的力学性能参数,选择Araldite 2015结构胶作为车身金属侧围板与复合材料地板装配连接的粘结材料,同时通过试验测试获得了其拉伸性能和剪切性能参数,并对复合材料地板进行了一体化集成设计,基于提出的PSO-BFO方法对铺层顺序进行多目标优化,解决了铺层顺序离散、爆炸组合和多变量的问题。优化结果表明,所提出的PSO-BFO方法对地板质量、静态弯曲刚度和白车身轻量化系数的改善率分别为34.4%、6.0%和5.3%。与PSO、BFO和PSO-GA的优化对比结果表明,PSO-BFO方法和PSO-GA均比单一优化算法更能获得复杂优化问题的全局最优解,但PSO-BFO方法得到的结果更为均衡,证明了所提出的方法能够有效解决碳纤维复合材料地板铺层多目标优化与设计问题。
  • *国家自然科学基金面上项目(51975244)
  • 吉林省自然科学基金项目(20220101200JC)
  • 吉林省中青年科技创新创业卓越人才(团队)项目(20230508050RC)
  • 2023嘉兴市重点研发计划项目(2023BZ10002)
  • 2024年嘉兴市公益性研究计划项目(2024AY10033)
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doi: 10.19620/j.cnki.1000-3703.20230915
  • 首发时间:2025-12-22
  • 出版时间:2024-08-24
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基金
*国家自然科学基金面上项目(51975244)
吉林省自然科学基金项目(20220101200JC)
吉林省中青年科技创新创业卓越人才(团队)项目(20230508050RC)
2023嘉兴市重点研发计划项目(2023BZ10002)
2024年嘉兴市公益性研究计划项目(2024AY10033)
作者信息
    1 嘉兴南湖学院,嘉兴 314001
    2 嘉兴市智能计算与数据科学重点实验室,嘉兴 314001
    3 吉林大学,汽车仿真与控制国家重点实验室,长春 130022
    4 零束科技有限公司,上海 201800
    5 戴姆勒大中华区投资有限公司上海分公司,上海 200080
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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