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Abstract
This paper presents the conducted research on an innovative pultrusion beam made of NCF carbon fabric for an enhanced flexural behavior. This includes laminate design and optimization. By changing the ply thickness of each 0°-, ±45°- and 90°- orientations (while fixing the others), their influence on the strength and stiffness of the pultrusion beam was studied by the finite element method. 7 different combinations of layups were designed to analyze mechanical performance. The simulation results show the layup of 4/5/1 ply ratio is the best one for strength and stiffness; therefore, the carbon fabric pultrusion beam samples were manufactured according to this layup. Bending experimental testing was conducted for both CFRP pultrusion beam and aluminum beam under the design case of equal thickness to compare their strength and stiffness. The testing results show the strength of fabric pultrusion beam is 82.5% of that of aluminum beam, weight is 60% of the aluminum one, and the stiffness is 75% of it. From the results obtained from FEA and physical testing, it is shown the pultrusion beam with complex multi-cavities shapes possess high mechanical performance. This research concludes the CFRP NCF pultrusion beam entails great advantages for railway structure parts and other industries.
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