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Integrated Design Method of Lightweight CFRP Lower Control Arms Using ABAQUS-Python Coupled Topology Optimization and Reconstruction of Continuous Fibre Paths
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DOI：10.3795/KSME-A.2026.50.3.211.png)
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Abstract
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Continuous carbon fibre reinforced plastics (CFRP) are attractive lightweight materials for automotive applications due to their high specific strength and stiffness. Recent advances in additive manufacturing enable improved structural performance through controlled continuous fibre path design. This study proposes an integrated design methodology combining ABAQUS-Python coupled topology optimization with G-code based continuous fibre path reconstruction to reduce the weight of a control lower arm. A cyclic multi load topology optimization framework was developed considering four representative loading conditions: pothole braking, reverse braking, outer cornering, and inner cornering. The method of moving asymptotes was employed to obtain the optimal material layout. Fibre paths were extracted from manufacturing G-code and reverse modelled into an ABAQUS finite element model using the embedded element method to represent interactions between the PETG matrix and carbon fibres. The results demonstrate feasibility for practical automotive structural applications.
Keywords:
Continuous Carbon Fibre Reinforced Plastic
Additive Manufacturing
Lower Control Arm
Topology Optimization
Journal
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IF:
0.2
Papers:
87
Citations:
308
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Cited Papers