Predicting Composite Component Behavior Using Element Level Crashworthiness Tests, Finite Element Analysis and Automated Parametric Identification

Fibre reinforced plastics have tailorable and superior mechanical characteristics compared to metals and can be used to construct relevant components such as primary crash structures for automobiles. However, the absence of standardized methodologies to predict component level damage has led to their underutilization as compared to their metallic counterparts, which are used extensively to manufacture primary crash structures. This paper presents a methodology that uses crashworthiness results from in-plane impact tests, conducted on carbon-fibre reinforced epoxy flat plates, to tune the related material card in Radioss using two different parametric identification techniques: global and adaptive response search methods. The resulting virtual material model was then successfully validated by comparing the crushing behavior with results obtained from experiments that were conducted by impacting a Formula SAE (Society of Automotive Engineers) crash box. Use of automated identification techniques significantly reduces the development time of composite crash structures, whilst the predictive capability reduces the need for component level tests, thereby making the development process more efficient, automated and economical, thereby reducing the cost of development using composite materials. This in turn promotes the development of vehicles that meet safety standards with lower mass and noxious gas emissions.