Prototyping a CFRP-aluminum automotive frame via multi-component anisotropic topology optimization
摘要
We present a case study of multi-component anisotropic topology optimization for structures made of multiple dissimilar materials. The method is based on multi-component topology optimization, where each component can have its own material properties and extended design variables or additional constraints. The first component consists of a conventional isotropic material, while the second is a three-dimensional anisotropic material. The anisotropic material is optimized using orientation tensors as extended design variables, which are simultaneously optimized. The method accommodates arbitrary combinations of isotropic and anisotropic materials, enabling the generation of optimal structures with complex geometries and material orientations. We apply this method to design a full-scale automotive semi-monocoque frame, which is fabricated through casting and tailored fiber placement and then assembled using nano-anodized bonding. Both numerical and experimental results demonstrate that the proposed method can achieve weight reduction and performance enhancement compared to conventional designs.