Contribution to the Optimization of Metal-Composite Lightweight Structures in Contextof Digital Linked Development Processes

Hybrid metal-composite structures offer high potential in lightweight engineering. These hybrid structures bring advantages in strength, stiffness and weight. These hybrid structures are predestined for highly stressed elements such as car body parts. The combination of the different materials leads to a complex process in the design as well as in the manufacturing phase with a multitude of adjustable and interacting parameters. This publication focuses on a deep understanding of the hybrid component to further support the development and digital observed manufacturing process. A stiffness-toweight improvement for the structure is presented. Potentially relevant parameters are identified from a wide range of geometric variables in each structural element. They were used to set up a parameterized model in SolidWorks and perform a CAD-based parametric FE simulation in ANSYS Workbench. The generated results are used to perform a sensitivity analysis to identify relevant parameters. These key parameters can be readjusted in the design process and provide the basis for a Digital Master in terms of geometry parameters.