Prototype fabrication of a composite automobile body based on integrated structure

This paper describes the integrated fabrication and assembly approach used to replace a steel body cover in Samand Sarir automobile by composite one because composite could perform higher mechanical performance, i.e., strength, stiffness, and impact absorption energy at low velocity. Considering the integrated body as base design criteria, the steel cover is redesigned and fabricated by composite material. Tensile, flexural, and charpy impact tests were carried out to determine the properties of woven fabric laminated composite in [0/90A degrees] and [+/- 45A degrees] fiber orientations. The selected composite laminate shows 2.9 times impact resistance; its desirability factors are improved 1.8 times for strength and 3.35 times for stiffness. Using finite element method, the impact of the composite body cover was simulated by ABAQUS for several thicknesses and fiber orientations. The FEM results indicate that finally laminated composite [0/90A degrees](7) can improve the crashworthiness of composite part in comparing to steel body cover. The integrated 3D preform of glass woven fabric was stitched like the shape of 3D model of body cover and placed in mold for prototype fabrication. It can be concluded that vacuum bagging as suggested fabrication method could be suitable for 3,000-5,000 annual production volume. Eventually, the fabricated composite body cover weighed 1.7 kg, which is 42% lighter than the steel body cover.