Abstract: Lightweight design for an aluminum lower control arm (LCA) is developed by using carbon sheet molding compound (C-SMC) and unidirectional prepreg tape (UD Tape) materials. Through the concept design and preliminary estimation, it is found that the optimization of fiber angel of UD tape during lay-up stacking can enhance the performance of structure along the main loading path strongly. Comparing to C-SMC and aluminum, anisotropic UD tape has more excellent mechanical property and design ability. Based on the UD Tape, we then developed the details of structure of LCA, and analysis the strength of the whole structure under the most dangerous load case and the strength of the joint between carbon fiber part and aluminum parts. Finally, we made a fatigue bench testing for LCA. The results show that CFRP LCA has remarkable lightweight effect, mechanical and anti-fatigue properties.

Key words: CFRP, low control arm, lightweight