Title: Design and certification of a composite thin-walled structure for energy absorption

Authors: Paolo Feraboli, Chris Norris, Doug McLarty

Addresses: Department of Aeronautics and Astronautics, University of Washington, Box 352400, Seattle, WA 98195-2400, USA. ' Swift Engineering Inc., San Clemente, CA 92673, USA. ' Swift Engineering Inc., San Clemente, CA 92673, USA

Abstract: Thin-walled Carbon Fibre Reinforced Polymer (CFRP) energy-absorbing devices have been successfully used in premier racing leagues to drastically improve the crashworthiness of a vehicle. Since their introduction in Formula 1 (F1) in the second half of the 1990s, the Rear Impact (RIMP) attenuators have received particular attention and their utilisation has been documented in scholarly publications. The engineering development and certification of the RIMP of the Star Mazda Racecar is discussed in detail. Quasi-static and dynamic crush tests are performed on two RIMP designs, featuring very different stacking sequences, are experimentally investigated. While the overall behaviour is quite different, they both exhibit the ability to collapse in a stable, progressive fashion. Furthermore, although the overall shape of the load-stroke diagram, energy absorption characteristics and failure behaviour have shown very good agreement, the quasi-static test results tend to substantially overestimate the effective dynamic energy absorption characteristics. The final RIMP design is selected based on its higher energy absorption and friendlier manufacturing characteristics.

Keywords: carbon fibre reinforced polymer; CFRP composites; crashworthiness; energy absorption; impact; destructive testing; racecars; crush tests; rear impact attenuators; vehicle design; automotive composites; racing cars; motor sport.

DOI: 10.1504/IJVD.2007.013642

International Journal of Vehicle Design, 2007 Vol.44 No.3/4, pp.247 - 267

Published online: 10 May 2007 *

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