Design Investigation Using Anisotropic Topology Optimization for Fabrication of Automotive Rear Frame with Variable Axial Composite by Tailored Fiber Placement

Abstract

This paper presents a design method for continuous fiber variable axial composites in three-dimensional space with locally varying orientation distribution under multi-loading conditions. The design method is formulated based on topology optimization by augmented tensor field design variables. An adaptive weighted sum method is formulated to fulfill design requirements. The fabrication method of designed structure is planned by Tailored Fiber Placement technology, whereby the preform is prepared by a CNC embroidery machine. The optimized composite design achieved comparable performance as the baseline aluminum frame with 15 % weight reduction.