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Lightweight B-pillar: CFRP Reinforced Crash Beam
2015 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

This is a report that describes the thesis work performed as a final step in Industrial Design Engineering at Luleå University. The project has been performed in behalf of Gestamp Hardtech in Luleå. Partners for this project were also a composite company named Swerea SICOMP located in Piteå. The task was to explore the possibility to reinforce one of Gestamp HardTech's components, a B-pillar, with a composite material. Theories regarding materials, manufacturing methods, FEM simulations and joining methods have been investigated. To generate ideas, workshops and brainstorming has been used together with test simulations in LS-DYNA. Reinforcement placement on the beam was investigated using simulations with varying steel patches. The results of these tests were then used to develop a set of concepts. The various concepts were further developed and crash simulations were performed to ensure proper behavior. Finally the two different concepts were detailed processed and optimized by thickness and geometry to achieve the desired buckling behavior. The concept development resulted in two different concepts that were manufactured by hand at Swerea Sicomp. The material used to manufacturing the prototypes was a carbon fiber fabric impregnated with a polymer. A total of five prototypes were manufactured and finally tested in the test hall at Gestamp Hardtech. The results of these tests were compiled and analyzed both in functionality and also compliance to previous simulations. The reduced weight of these concepts is around 68% for the patch corresponding to a weight reduction of 16% on the entire beam. As a final step the results were discussed and recommendations for future work were developed.

Place, publisher, year, edition, pages
2015. , 66 p.
Keyword [en]
Technology, Carbon fiber reinforce polymer, Crash beam, Composite, Crash simulation, LS-DYNA, Reverse engineering
Keyword [sv]
URN: urn:nbn:se:ltu:diva-56547Local ID: d4e2b17b-cde0-41af-aaaf-6b2728fe20f1OAI: diva2:1029934
External cooperation
Subject / course
Student thesis, at least 30 credits
Educational program
Industrial Design Engineering, master's level
Validerat; 20150318 (global_studentproject_submitter)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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