The hybrid design under study here is expected to withstand similar ultimate loads as that of the original all metal parts. The challenge is to combine the high strength uni-directional fibre composite tape with appropriate number of plies into a stable arrangement with a strong enough plastic around it and ensure well distributed load path. From simulation point of view also, the challenges are in terms of representing with 3D elements with orthotropic material properties as against conventional 2D elements and to incorporate contacts that represent the realistic behaviour.

These calibrations and design updates took few iterations before arriving at an optimised design. With this design, a good amount weight savings can be expected as well as cost of production when produced in a bigger number. Download whitepaper to continue reading.