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<p>To enhance the crashworthiness, energy absorption, and lightweight level of automotive B-pillar assemblies, this study proposes a synergistic multi-material design, optimization, and molding methodology for high-strength steel-carbon fiber composite B-pillars. An improved PSO-BFO hybrid algorithm and multi-level layer optimization method are used to design the carbon fiber composite inner panel, while a dynamic-static constrained multi-objective optimization method optimizes the thickness distribution of the high-strength steel outer panel, yielding a variable-thickness structure. A finite element model is validated via drop hammer impact testing, and T300/5208 material properties are obtained to optimize inner panel layups. Free-size and size optimizations determine the layup shape and thickness, with the PSO-BFO algorithm optimizing the layup sequence. Eight thickness variables drive multi-objective lightweight optimization of the outer panel. After optimization, the B-pillar assembly achieves 0.5% weight reduction, with tensile/compressive stiffness improved by 16.98%, lateral/rear bending stiffness by 23.38%/11.24%, first-order bending/torsional modes by 15.21%/13.16%, and drop hammer impact displacement reduced by 17.34%. Integrating carbon partitioning into hot stamping overcomes single-step forming challenges, while a derived one-dimensional permeability formula optimizes composite molding. Tests show ≤ 4% simulation-test error, validating the approach's effectiveness.</p>

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Study on Lightweight Design of Automobile B-pillar Structure and Process with Variable-Thickness High-strength Steel Outer Plate-Carbon Fiber Composite Inner Plate

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Shuai Zhang,
  • Mengbao Guo,
  • Zhao Li,
  • Feng Xiong,
  • Zhiqiang Xi,
  • Yiliu Wang,
  • Heng Deng,
  • Hao Zhang,
  • Mi Yan,
  • Yuzhuo Zhang

摘要

To enhance the crashworthiness, energy absorption, and lightweight level of automotive B-pillar assemblies, this study proposes a synergistic multi-material design, optimization, and molding methodology for high-strength steel-carbon fiber composite B-pillars. An improved PSO-BFO hybrid algorithm and multi-level layer optimization method are used to design the carbon fiber composite inner panel, while a dynamic-static constrained multi-objective optimization method optimizes the thickness distribution of the high-strength steel outer panel, yielding a variable-thickness structure. A finite element model is validated via drop hammer impact testing, and T300/5208 material properties are obtained to optimize inner panel layups. Free-size and size optimizations determine the layup shape and thickness, with the PSO-BFO algorithm optimizing the layup sequence. Eight thickness variables drive multi-objective lightweight optimization of the outer panel. After optimization, the B-pillar assembly achieves 0.5% weight reduction, with tensile/compressive stiffness improved by 16.98%, lateral/rear bending stiffness by 23.38%/11.24%, first-order bending/torsional modes by 15.21%/13.16%, and drop hammer impact displacement reduced by 17.34%. Integrating carbon partitioning into hot stamping overcomes single-step forming challenges, while a derived one-dimensional permeability formula optimizes composite molding. Tests show ≤ 4% simulation-test error, validating the approach's effectiveness.