Design and optimization of tapered carbon‐fiber‐reinforced polymer rim for carbon/aluminum assembled wheel

Abstract A multi‐objective integrated optimization framework that considers the manufacturing process in the design of a tapered carbon‐fiber‐reinforced polymer (CFRP) rim structure was established. Firstly, the three‐zone symmetrically stacked CFRP rim structure was proposed and modeled. The bending and radial fatigue and 13° impact of the carbon/aluminum‐assembled wheel composed of CFRP rim and aluminum alloy spoke were analysed. Coupling lay‐up thickness, sequence and angle as design variables, multi‐objective integrated optimization design for the tapered CFRP rim structure was performed through radial basis function neural network surrogate model combined with an elitist non‐dominated sorting genetic algorithm approach. Pareto‐optimal solutions were obtained, and the trade‐off solution was selected through grey relational analysis coupled with entropy weighting method. Finally, the tapered CFRP rim was manufactured through molding and autoclave forming technology. The CFRP rim has a weight saving of 17.2% compared with the previously developed forged magnesium alloy rim of the same size. The bending and radial fatigue and 13° impact performance of the assembled wheel were then validated by corresponding physical test, results of which met GB 36581‐2018 standard.