Abstract: To improve the product performance and meet the design concept of lightweight,a'composite structure integration'forming and lightweight structure optimization method based on thermoplastic continuous fiber layer was proposed.Taking the safety helmet shell as the carrier,the optimization effects and advantages of this method in the rapid forming and service process of glass fiber composites with thermoplastic resin as the matrix were described in detail.Through the combination of material optimization and topology optimization,the two processes of molding and injection molding were seamlessly integrated to realize the lightweight manufacturing of helmets.The results showed that compared with the conventional injection process helmet,the weight of the helmet shell using thermoplastic continuous glass fiber composite material and topology optimization structure decreased by 6% under the premise of maintaining the same stiffness,and the thinning rate reached 29.7%.Material optimization and topology optimization provide more degrees of freedom for the design of the overall helmet and increase the optimization space for wearing comfort.

Key words: thermoplastic continuous fiber composites, topological optimization, “composite structure integration”forming, safety helmet

摘要： 为了提高产品性能并满足轻量化的设计理念,提出一种基于热塑性树脂连续纤维铺层的“复材结构一体化”快速成形/型与轻量化结构优化方法。并以安全头盔外壳为载体,较详细地阐述该方法在以热塑性树脂为基体的玻璃纤维复合材料的快速成形/型以及服役过程中的优化效果和优势。通过采用材料优化和拓扑结构优化相结合的方法,将模压成型和注塑成型两大工艺无缝集成,实现头盔的轻量化制造。结果表明:相比常规的注塑工艺头盔,在刚度保持相同的前提下,使用热塑性连续玻璃纤维复合材料和拓扑优化结构的头盔外壳的重量下降6%,减薄率达到29.7%。材料优化和拓扑优化为整体头盔的设计提供了更多自由度,增加了佩戴舒适度的优化空间。

关键词: 热塑性连续纤维复合材料, 拓扑优化, “复材结构一体化”成形/型, 安全头盔