- 學位論文
可量產性設計複材車體結構之研究
Composites Body Design for Mass Production Research
摘要
本研究以提高複合材料三明治車體結構產量為主要目標。傳統的複材車體結構大都以單體式結構為主，其製作流程繁鎖，需大量人工，使得產量無法提升，因此本研究採用目前最為普遍的(body in white)素車體結構並且針對複材的可製造性以及受力型式，修正原有的複材車體結構設計流程。 論文首先探討自動化製程對複材結構件成型上的限制，再利用FEM計算車體結構在靜態剛性模擬、強度模擬，並且以最大主軸應力分析其應力的向量方向，藉此判斷其纖維結構件是否需要連續，避免在實際受力時的應力集中，以及纖維較為需要連續的地方產生破壞。在估算結構件間的接合強度，其破壞模式因較為複雜，因此本研究採用ABAQUS Cohesive Element模擬膠層破壞，並且提出“接合強度判斷流程”，簡化其複雜的分析模型，以實驗驗證流程及分析的準確性，續利用此套方法計算T-Joint、Lap-Joint幾何參數對負載強度的影響。最後將其接合型式對負載強度的影響，帶入全車的簡化模型，確認其初步的設計是否可以達到要求。 對於日益苛求重量之節能車輛，根據本論文的複材素車體結構設計流程，可設計出兼顧量產的方便性，以及剛性、強度需求的複材素車體結構，達到可量產且遠低於傳統金屬結構重量之理想複材車體結構。
並列摘要
The target of this research is to enhance the production efficiency of composite sandwich automobile structure. The most common used structure, body in white, is adopted and modified by this research to revise the design process by the manufacturability and exerted force type to replace the traditional monoque structure, which acquires a series of cumbersome and labor intensive manufacture process. In the beginning, the limit of automatic forming process of carbon sandwich composites has been investigated. Followed by the simulations about the static stiffness and strength of the car structure, and obtain the direction of capital stress in the structure to judge whether the continuity of the fabric is needed in each part of the structure to avoid stress concentration and failure in places where fabric has to be continuous. In the research, a "Judging Jointing Strength Process" is proposed and using ABAQUS Cohesive Element, simplify traditional complex model that is applied to predict jointing type load capacity. Moreover, this process is verified by comparing the result with two T-joint failure mode and applied different joint-type design. Final, joint type affect load capacity applied into a simplified vehicle model, whether confirmed preliminary design reach the requirements.