Aleksandr Pochezhertsev
Topic
Reinforced Composite-Based Structure for Lightweight Machinery
Modern heavy work machines suffers from excessive mass due to the predominant use of steel structures, leading to high energy consumption and low efficiency. Replacing steel with composites is limited by their anisotropy, cost, and technological constraints for complex geometries. There is a clear need for a weight reduction methodology for steel components while maintaining strength and manufacturability, through combined lightweighting of steel and targeted composite reinforcement.
A unified framework is being developed for the optimisation of hybrid steel–composite structures. The method integrates:
• Parametric and topology optimisation of steel components to achieve minimum feasible mass under strength and stiffness constraints.
• Integration of composite reinforcements, optimised in placement, fibre orientation, and stacking sequence, considering anisotropy and manufacturing feasibility.
• Numerical modelling (FEM) accounting for contact and adhesive interfaces between materials.
• Multi-level optimisation, combining structural, technological, and material parameters into a single optimisation pipeline.
The proposed methodology enables substantial reduction of mass and inertia of machine structures without loss of load-bearing capacity. This translates into improved energy efficiency, dynamic performance, and overall sustainability. The resulting framework provides engineers with a practical tool for rational co-design of steel and composite elements, while accounting for real manufacturing constraints.
Existing lightweight design approaches rely either on topology optimisation of metallic components only or on full composite substitution. The former is limited by material density and stiffness; the latter by cost and manufacturing complexity. Current hybrid methods lack an integrated way to include multiple interacting parameters — geometric, mechanical, and technological — within one optimisation process. The proposed framework fills this gap by providing a systematic and holistic approach to hybrid structure design.