LAUSR

An integrated optimization that comprehensively considers design and manufacturing factors such as the geometric appearance, laminate constitutions, laminate distribution, laminate thickness and stacking sequence, is proposed for designing a carbon fiber reinforced polymer wheel hub of a racecar. First, the driving conditions of the racecar are analyzed to determine the performance requirements. Then, under the condition that the geometric design regions are partitioned and the constitutions of fiber plies with different directions are defined, laminate design and manufacturing model is established. A multi-objective optimization is then performed to achieve a lightweight, high-stiffness laminate structure in different design regions. Next, number of plies in each region is obtained from the thickness of laminate, and then, the stacking sequence is optimized to improve the stiffness of the laminate structure. Finally, laminate transitions for different regions are investigated. The results showed that laminate design and manufacturing optimization can reduce the weight of the wheel hub and improve the performance of the wheel hub under static, dynamic and impact conditions. The proposed optimization approach provides a feasible solution for a performance-based design of composite structures.