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Title : Composite Crush Simulation – Emerging Technologies And Methodologies
Company : SIMULIA
File Name : composite-crush-simulation-emerging-technologies-2008.pdf
Size : 36721
Type : application/pdf
Date : 09-Jul-2011

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In the quest to lower environmental impact while maintaining vehicle performance, automakers and aerospace companies are knocking on the same door – that is, increasing use of composite materials in order to reduce structural mass. It can be expected that material costs will drop considerably over the next few to several years, as the capacity to produce such materials begins to catch up with the growing demand. The benefits of using these materials are well-documented, including their substantial capacity to absorb energy in an impact scenario. Composite structures generally behave much differently than their metallic equivalents in a crash event when subjected to large compressive and dynamic forces. Whereas a metal structure will typically undergo large plastic deformations to absorb the kinetic energy of the event, a well-engineered composite member subjected to large axial compression will pulverize in a progressive manner from one end to the other as the “crush front” moves along its length. The crush front is characterized by numerous microscopic interactions between fiber and matrix, and efficient energy absorption can be achieved when the moving crush front becomes essentially a continuous event, traversing steadily along the length of the composite member. However, it is also this type of crushing failure which can prove difficult to simulate using conventional finite element methods. CZone technology has been developed to bridge the gap between experimental observations regarding a material’s ability to absorb energy in an impact and the need to understand complex structural interaction and stability in a largerscale crash event. CZone technology is being incorporated as an add-on product for Abaqus/Explicit in order to provide a predictive capability for composite crush scenarios—the CZone functionality handles the material’s behavior at the crush front, while the damage and failure models in Abaqus/Explicit address the integrity of the backup structure. This paper will demonstrate the technology in action on some automotive scale structures and will identify the additional material characterization required to successfully predict their performance in crash.
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