A hydraulic cylinder barrel of flange carbon fiber reinforced plastics (CFRP) with metal lining was developed.The stress-strain formula of CFRP barrel was derived by the constitutive relation of composite material and the theory of thick-walled cylinder,and the mathematical model was established.Combined with the strength and stiffness theory,the lightweight of hydraulic cylinder barrel was studied.Abaqus software was used for simulation analysis to verify the feasibility of the proposed scheme.Combined with Isight software,the optimization design was carried out to find the optimal solution by DOE experimental design.The results show that the CFRP cylinder can meet the strength and stiffness requirements after optimization design.The weight of the hydraulic cylinder is reduced from 16.58 kg to 5.26 kg,and the overall weight is reduced by 68.3%,and the purpose of lightweight design is achieved.