Title: Finite element simulation for predicting the behaviour of carbon fibre tubes for automotive side structure

Authors: Balaji Pillai; C. Lakshmana Rao; Naresh Kulkarni

Addresses: Mercedes Benz Research and Development India, Bangalore, 560066, India ' Department of Applied Mechanics, IIT Madras, Chennai, 600 036, India ' Mercedes Benz Research and Development India, Bangalore, 560066, India

Abstract: Digital product development for carbon fibre reinforced polymer (CFRP) parts needs reliable simulation methods to predict the performance. The objective of this study to find the best simulation method to predict the behaviour of CFRP tube when subjected to lateral/bending forces. LS Dyna Explicit finite element code is used for simulation. CFRP square tube is subjected to three Point bend test experiment. The force displacement curves are obtained. The deformation pattern, cracks and failures are also closely observed. Various methods of Finite Element Simulation are explored. Each simulation method is compared with experimental results. Finite element simulation method with Layered Thin Shell and delamination modelling using mixed mode material cohesive zone is found to be best validating with experimental results. This method is proposed to be used in the design and development of Carbon fibre parts for automotive structures. This can reduce time and cost involved in prototyping and testing.

Keywords: FEA; finite element analysis; carbon fibre; CFRP; carbon fibre reinforced polymer; composite tubes; bending experiment; delamination; tie break; cohesive zone modelling; LS Dyna; MAT_054; thick shell; thin shell.

DOI: 10.1504/IJAUTOC.2018.10016302

International Journal of Automotive Composites, 2018 Vol.4 No.1, pp.28 - 51

Received: 17 Nov 2017
Accepted: 16 Apr 2018

Published online: 21 Sep 2018 *

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