Design of a composite engine support sub-frame to achieve lightweight vehicles

The main objective of this paper is to analyze the possibility of the replacement of the engine sub-frame, which at present is made of steel or in some advanced cases in lightweight metals, with a new component made of Carbon/Epoxy composite material. A methodology is developed that helps to point out and solve the existing major problems with respect to the use of composite structures, by taking advantage from composite features such as the effect of variation of stacking sequence, ply angles, and stiffeners on load carrying capacity and stiffness of engine sub-frame. Furthermore, detailed numerical analysis has been performed to determine the natural frequencies and modes shapes of the proposed solutions. Results show competitive performance (with particular attention to the equivalent stiffness and natural frequency) of the new proposed solution based on composite material with respect to thereference steel sub-frame solution