University of Twente Student Theses


Conceptual design of a thermoplastic composite cross-car beam

Kajim, A.C.C. (2023) Conceptual design of a thermoplastic composite cross-car beam.

[img] PDF
Abstract:Thermoplastic composites (TPCs) have garnered interest in the automotive world due to their potential for lightweighting. However, several challenges limit widespread adoption. This thesis aims to design a continuous fiber TPC high-volume ready structural cross-car beam and to provide an overview of the challenges in the analysis and implementation of a TPC structural part. By giving an overview of the literature and by simulations. TPCs can be manufactured at the required cycle time for high-volume production using pick and place for blank forming and press forming followed by overmolding. The research highlights the complexity of composite part design and simulation, particularly in optimizing variables such as fiber angles and local reinforcements, and addressing anisotropic behavior and production-related issues affecting strength significantly. This report focuses only on stiffness simulations, as especially strength and crash simulations require advanced validated material models, which were not available at the start of this thesis. Weight reduction compared to an aluminum CCB was found to be challenging using glass fiber. This was only possible by lowering the eigenfrequency requirement, possible due to the superior damping properties of composites. Despite this, the cost of the weight saving exceeds acceptable levels in automotive.
Item Type:Essay (Master)
Lightyear, Helmond, The Netherlands
Faculty:ET: Engineering Technology
Subject:52 mechanical engineering
Programme:Mechanical Engineering MSc (60439)
Link to this item:
Export this item as:BibTeX
HTML Citation
Reference Manager


Repository Staff Only: item control page