This edition first published 2019
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Library of Congress Cataloging‐in‐Publication Data
Names: Kobelev, Vladimir, 1959‐ author.
Title: Design and analysis of composite structures for automotive
applications : chassis and drivetrain / Vladimir Kobelev, Department of
Natural Sciences, University of Siegen, Germany.
Description: First edition. | Hoboken, NJ : Wiley, 2019. | Series: Automotive
series | Includes bibliographical references and index. |
Identifiers: LCCN 2019005286 (print) | LCCN 2019011866 (ebook) | ISBN
9781119513841 (Adobe PDF) | ISBN 9781119513865 (ePub) | ISBN 9781119513858
(hardback)
Subjects: LCSH: Automobiles–Chassis. | Automobiles–Power trains. |
Automobiles–Design and construction.
Classification: LCC TL255 (ebook) | LCC TL255 .K635 2019 (print) | DDC
629.2/4–dc23
LC record available at https://lccn.loc.gov/2019005286
Cover Design: Wiley
Cover Images: © Vladimir Kobelev, Background: © solarseven/ShuWerstock
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From a materials science point of view, composite materials of glass and carbon fibers have a specific potential and already some practical importance in several applications under high dynamic loads. Comparing the fibers, glass fibers are the better material for spring applications because their lower modulus of elasticity compared to carbon fibers. This is favorable in terms of high strokes and deformation requirements. Due to their high specific strength and the stiffness of composite materials, it is in principle possible to achieve weight savings of 30 – 70% of the weight of a steel spring depending on application. In addition to reduce the unsprung masses for suspension, it is also possible to improve driving dynamics as well as noise, vibration and hardness behavior (NVH), since the material properties are better in some significant areas. Furthermore, due to the high corrosion resistance and resistance against other environmental influences, surface protection is not necessary in most of the applications.
However, the usage of composite materials for springs have not reached high quantities due to some limitations. Load transmission requires special designs. Considering suspension coil springs, high loads transverse to the main load direction occur. Therefore, the load transmission does not follow ideally to the fiber direction and only medium loads can act on the matrix. In addition, in the case of large‐scale production and the available manufacturing processes, value adjustments must be made in comparison with units made of steel. These are currently the focus of research and development efforts throughout the world. Endless, unidirectional fiber materials, such as those used for structural elements in automotive engineering, exhibit strong anisotropic, i.e. direction‐dependent, properties. The fibers used are oriented with respect to the loads that occur. Therefore, the leaf spring, where loading results almost in tension stresses of the fibers is the perfect match with composite materials. Huge weight reduction up to 75% is possible to achieve by using the material properties and the design flexibility of glass fiber reinforced composite in the best way. A single composite tension leaf spring can substitute a steel multi‐leaf spring with a progressive spring load characteristic. The special design leads to a very homogenous, progressive spring characteristic and therefore, a better driving performance. Furthermore, we know already some designs for suspension steel coil springs substitution such as one‐by‐one substitution by composite coil spring and a meander spring design. In both case these springs do need special tools for the design and did not reach the market breakthrough due to huge different load‐rate requirements within the platforms.
There are some processes existing for the production of glass fiber composite springs. Nevertheless, the prepreg process (pre‐impregnated fibers) has proven itself as the best due to the realizable good properties under dynamic loads. Prepreg processes result in an optimal adhesive strength due to low porosity and allows flexibility in design, such as geometry, width and height of the spring. It is also possible to produce the elements of chassis in general and suspension particular using the resin injection process. For this resin injection process, a fiber structure is first produced from the dry reinforcement fibers, which follows the desired component geometry. If required, structural cohesion can be achieved using textile methods, such as sewing or bonding, which bond the fibers together. Such fiber structures are called preforms. The injection of the resin influences the orientation of the fibers and therefore, those springs do not reach the performance of prepreg composites due to potential ondulation.
Automotive manufacturers' requirements for carbon dioxide reduction, lower vehicle weight, the reduction of unsprung masses and the robustness of the springs, especially in the event of corrosion, will further increase in the future. The optimal application of the materials used plays a decisive role, supported by material properties, best technology and processes as well as an efficient design. Therefore, alternative materials, such as composites, may become higher importance for dynamic loaded suspension applications.
Prof. Dr. Vladimir Kobelev was born in Rostow‐na Donu, Russian Federation. He studied Physical Engineering at the Moscow Institute of Physics and Technology. After his PhD at the Department of Aerophysics and Space Research (FAKI), he habilitated at the University of Siegen, Scientific‐Technical Faculty. Today, Prof. Kobelev is lecturer and APL professor at the University of Siegen in the subject area of Mechanical Engineering.
In his industrial career, Prof. Kobelev is an employee at Mubea, a successful automotive supplier located near Cologne/Germany. In the Corporate Engineering Department, Prof. Kobelev is responsible for the development of calculation methods and physical modeling of Mubea components.
Joerg Neubrand
CTO, Managing Director and
Member of the Executice Board of the Mubea Group
Fuel efficiency continues to “drive” significant research and development in the automotive sector. In many instances, this is propelled by regulations that target reduced emissions as well as reduced fuel consumption. Even with more efficient vehicles and electric hybrid or purely electric driven systems, the need for reduced energy consumption is demanded by the market. This is due to the fact that the customer base is demanding increased efficiency as this brings better performance, lower costs and extended range of the vehicle. One clear means by which fuel efficiency can be enhanced is by reducing the weight of the vehicle. Lightweighting can be accomplished by a number of means, one of which is lighter weight material substitution. That is to say, one may substitute a lighter material for a heavier one on a vehicle component. Composites have been used to replace metal components in efforts to lightweight aircraft for decades. More recently, advances in materials, manufacture, and design have made composites cost effective and viable in the automotive sector. Two major stumbling blocks that have hindered composite use in the automotive sector are the cost of the composite components, and the ability to rapidly and economically produce such components in quantities that are needed by the automotive sector. Recently, these stumbling blocks have been overcome. However, for most commercial automotive applications, composites remain relegated to less critical elements of the vehicle system such as body panels. The use of composite for more critical vehicle applications such as suspension and drive train elements have been left to extremely demanding automotive scenarios such as Formula One. However, this scenario is about to change.
Design and Analysis of Composite Structures for Automotive Applications, provides an in‐depth technical analysis of critical suspension and drive train elements with a focus on composite materials. This includes basic principles for the design and optimization of critical vehicle elements using composite materials, as well as classical concepts related to mass reduction in automotive systems. The author, Professor Kobelev, skillfully integrates concepts related to vehicle parameters such as stiffness into overall vehicle dynamics using closed form solutions that are described in exquisite detail. The discussions focus on key elements of the vehicle including suspension and powertrain. These discussions are both comprehensive as well as the first of their kind in a text book, making this text an important reference for any automotive engineer on the leading edge.
Design and Analysis of Composite Structures for Automotive Applications is part of the Automotive Series that addresses new and emerging technologies in automotive engineering, supporting the development of next generation vehicles using next generation technologies, as well as new design and manufacturing methodologies. The series provides technical insight into a wide range of topics that is of interest and benefit to people working in the advanced automotive engineering sector. Design and Analysis of Composite Structures for Automotive Applications is a welcome addition to the Automotive Series as it primary objective is to supply pragmatic and thematic reference and educational materials for researchers and practitioners in industry, and postgraduate/advanced undergraduates in automotive engineering. The text is a state‐of‐the art book written by a leading world expert in composites and its application to suspensions and is a welcome addition to the Automotive Series.
Thomas Kurfess
March 2019