Design Optimization of Composite Lay-up Sequence and Orientation to Achieve Minimum Weight for Racing Seat

Composites have proved their usefulness in the automotive industry during recent years. Many automobile companies use them in different parts to reduce weight without hampering strength. In a composite material, Lay-up sequence and orientation highly affects the properties of the laminate. Therefore, it is important to perform design optimization on a component to achieve high strength in minimum weight. This paper deals with the optimization of lay-up for composite Racing Seat using finite element analysis. Different lay-up sequences for laminates including, cross-ply [0/90]n, angle-ply [±α]n, and [0/90/±α]n are analysed. The lay-up sequence, orientation and ply number are optimized using composite material carbon fibre/Epoxy. Driver’s ergonomics and impact sustainability are considered constraints for weight optimization. Driver’s ergonomics were based on 95th percentile male and 5th percentile female rule. Force analysis is performed on the seat according to SFI 39.2 to evaluate the strength requirement. Finite element analysis of composite racing seat is performed via commercial finite element code ANSYS and using the capabilities of ANSYS Composite PrepPost (ACP) to form desired composite lay-up. A finite element code is based on classical lamination theory; including Puck’s failure criterion for first-ply failure. The seat is divided into three portions with a different number of layers considering the values and specific nature of acting forces; which resulted in different thicknesses in different regions. The optimization results show that for all the angles of Angle-ply laminate considered, Angle-ply laminates with an angle of 45⁰ provides a more optimum design. The minimum weight obtained is 10.15 kg.