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Development of Dynamic Test Method and Optimisation of Hybrid Carbon Fibre B-pillar
Luleå University of Technology, Department of Engineering Sciences and Mathematics.
Luleå University of Technology, Department of Engineering Sciences and Mathematics.
2017 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

The strive for lower fuel consumption and downsizing in the automotive industry has led to the use of alternative high performance materials, such as fibre composites. Designing chassis components with composite materials require accurate simulation models in order to capture the behaviour in car crashes. By simplifying the development process of a B-pillar with a new dynamic test method, composite material products could reach the market faster. The setup has to predict a cars side impact crash performance by only testing the B-pillar in a component based environment. The new dynamic test method with more realistic behaviour gives a better estimation of how the B-pillar, and therefore the car, will perform in a full-scale car side impact test.

With the new improved tool for the development process, the search for a lighter product with better crash worthiness is done by optimising a steel carbon fibre hybrid structure in the B-pillar. The optimisation includes different carbon fibre materials, composite laminate lay-up and stiffness analysis. By upgrading simulation models with new material and adhesive representation physical prototypes could be built to verify the results.

Finally the manufactured steel carbon fibre hybrid B-pillar prototypes were tested in the developed dynamic test method for a comparison to the steel B-pillar. The hybrid B-pillars perform better than the reference steel B-pillar in the dynamic tests also being considerably lighter. As a final result a hybrid B-pillar is developed that will decrease fuel consumption and meet the requirements of any standardized side impact crash test. 

Abstract [sv]

Strävan efter lägre bränsleförbrukning och minimalistiskt tänkande inom bilindustrin har lett till användning av alternativa högpresterande material, såsom fiberkompositer. Vid design av chassi-komponenter utav kompositer krävs noggranna simuleringsmodeller för att fånga upp bilens beteende vid en krock. Genom att förenkla utvecklingsprocessen för en B-stolpe med en ny dynamisk testmetod kan produkter bestående av fiberkompositer nå marknaden snabbare. Provuppställningen skall förutse bilens prestanda vid ett sidokrocktest genom att endast testa B-stolpen i en komponentbaserad miljö. Den nya dynamiska testmetoden med ett mer realistiskt beteende skall ge en bättre uppskattning om hur B-stolpen, och därmed bilen, kommer att prestera i ett fullskaligt sidokrocktest.

Med utvecklingsprocessens nya förbättrade verktyg kan strävan mot lättare produkter med bättre krocksäkerhet utvecklas genom optimering av en hybrid B-stolpe i stål och kolfiber. Optimeringen innefattar olika kolfibermaterial, laminatvarianter och styvhetsanalyser. Genom att uppgradera simuleringsmodeller med nya material och adhesiva metoder kunde fysiska prototyper tillverkas för att verifiera resultaten.

Slutligen testades de tillverkade prototyperna utav stål och kolfiber i den nyutvecklade dynamiska testmetoden för jämförelse mot den ursprungliga stål B-stolpen. Hybrid B-stolparna presterade bättre än referensstolpen utav stål i de dynamiska provningarna och är samtidigt betydligt lättare. Det slutgiltigt resultatet är en utvecklad hybrid B-stolpe som både ger minskad bränsleförbrukningen och uppfyller kraven för ett standardiserat sidokrocktest. 

Place, publisher, year, edition, pages
2017. , 74 p.
Keyword [en]
Dynamic test method, B-pillar, Crash worthiness, Side impact crash test, IIHS, Carbon fibre reinforced polymer composite, Composite failure, CFRP, UD, 2x2 Twill, Delamination, Finite Element Method, LS-Dyna, Steel-composite interface, Bilinear fracture toughness
National Category
Composite Science and Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-65128OAI: oai:DiVA.org:ltu-65128DiVA: diva2:1133906
External cooperation
Gestamp Hardtech
Subject / course
Student thesis, at least 30 credits
Educational program
Mechanical Engineering, master's level
Supervisors
Examiners
Available from: 2017-08-25 Created: 2017-08-17 Last updated: 2017-08-25Bibliographically approved

Open Access in DiVA

The full text will be freely available from 2022-08-15 08:00
Available from 2022-08-15 08:00

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