Process investigation for ultra-lightweight hybrid UD prepreg and CFSMC carbon fibre vehicle components

Abstract

[EN] Demonstration of a compression moulding process which combines carbon fibre sheet moulding compound (CFSMC) and local reinforcements with unidirectional (UD) prepreg is done for an actual motorcycle component, specifically a footrest bracket from Métisse Motorcycles. Along this project, different UD reinforcement configurations over the CFSMC for the part have been analysed by means of both a finite element model and experimental testing. In this way, the most influencing areas were reinforced while minimising the amount of UD material. This allows containing the increase in material costs but increasing performance with respect the pure CFSMC based design. On the other hand, other materials have been used to test the viability of the process with materials such as core foams or recycled carbon fibres which would allow the part to be respectively lighter or cheaper, but having a drop on its mechanical properties. Hybridisation and alternative materials are different options to modify the original design to improve weight, stiffness, strength and/or material cost. They have a vast amount of combinations which help to optimise the component for different applications but always considering mass production requirements. Qualitative experimental testing was carried out to determine which configuration is better for the footrest bracket according to each of the mentioned parameters.

[ES] Desarrollo de metodologías para la fabricación por moldeo de compresión en componentes complejos de fibra de carbono para el sector de automoción. El objetivo es demostrar la automatización y reducción de costes para fabricar con materiales compuestos a gran escala, utilizando CFSMC con refuerzos locales de pre-impregnado unidireccional.