Advanced Composite Materials for Automotive Applications

EditorAhmed Elmarakbi – University of Sunderland, UK

• About the Editor xv List of Contributors xviiSeries Preface xxiPreface xxiiiPart One FUNDAMENTAL BACKGROUND1 Overview of Composite Materials and their Automotive Applications 3Ali Hallal, Ahmed Elmarakbi, Ali Shaito and Hicham El-Hage1.1 Introduction 31.2 Polymer Composite Materials 51.3 Application of Composite Materials in the Automotive Industry 121.4 Green Composites for Automotive Applications 171.5 Modelling the Mechanical Behaviour of Composite Materials 191.6 Discussion 221.7 Conclusion 23References 242 High-Volume Thermoplastic Composite Technology for Automotive Structures 29Neil Reynolds and Arun Balan Ramamohan2.1 Introduction – Opportunities for Thermoplastic Composites 292.2 Recent Developments in Automotive TPCs 312.3 Case Study: Rapid Stamp-Formed Thermoplastic Composites 342.4 Conclusion 48Acknowledgements 49References 493 Development of Low-Cost Carbon Fibre for Automotive Applications 51Alan Wheatley, David Warren, and Sujit Das3.1 Introduction 513.2 Research Drivers: Energy Efficiency 523.3 Lightweight Automotive Materials 533.4 Barriers to Carbon Fibre Adoption in the Automotive Industry 553.5 Global Production and the Market for Carbon Fibre 583.6 Low-Cost Carbon Fibre Programme 603.7 International Cooperation 72Acknowledgements 72References 72Part Two IMPACT AND CRASH ANALYSIS4 Mechanical Properties of Advanced Pore Morphology Foam Composites 77Matej Vesenjak, Lovre Krstulovi´c-Opara and Zoran Ren4.1 Introduction 774.2 Cellular Materials 784.3 Advanced Pore Morphology Foam 834.4 Mechanical Properties of Single APM Foam Elements 844.5 Behaviour of Composite APM Foam 894.6 Conclusion 96Acknowledgements 96References 965 Automotive Composite Structures for Crashworthiness 99Dirk H.-J.A. Lukaszewicz5.1 Introduction 995.2 Traffic Safety 995.3 Alternative Vehicles 1015.4 Selective Overview of Worldwide Crash Tests 1035.5 Structural Crash Management 1065.6 Composite Materials for Crash Applications 1105.7 Energy Absorption of Composite Profiles 1155.8 Conclusion 124Acknowledgements 125References 1256 Crashworthiness Analysis of Composite and Thermoplastic Foam Structure for Automotive Bumper Subsystem 129Ermias Koricho, Giovanni Belingardi, Alem Tekalign, Davide Roncato and Brunetto Martorana6.1 Introduction 1296.2 Materials for Automotive Applications 1326.3 Composite and Thermoplastic Materials 1336.4 Numerical Modelling of Fiat 500 Frontal Transverse Beam 1376.5 Standards for Low-Speed Frontal Impact 1416.6 Bumper Beam Thickness Determination 1416.7 Results and Discussion 1426.8 Conclusion 145References 1467 Hybrid Structures Consisting of Sheet Metal and Fibre Reinforced Plastics for Structural Automotive Applications 149Christian Lauter, Thomas Tr¨oster and Corin Reuter7.1 Introduction and Motivation 1497.2 Conventional Method for the Development of Composite Structures 1507.3 Approaches to Automotive Lightweight Construction 1517.4 Requirements for Automotive Structures 1547.5 Simulation 1587.6 Manufacturing 1607.7 Testing 1657.8 New Methodology for the Product Engineering of Hybrid Lightweight Structures 1707.9 Conclusion 172References 1728 Nonlinear Strain Rate Dependent Micro-Mechanical Composite Material Model for Crashworthiness Simulation 175Ala Tabiei8.1 Introduction 1758.2 Micro-Mechanical Formulation 1758.3 Strain Rate Dependent Effects 1888.4 Numerical Results 1978.5 Conclusion 203References 2039 Design Solutions to Improve CFRP Crash-Box Impact Efficiency for Racing Applications 205Simonetta Boria9.1 Introduction 2059.2 Composite Structures for Crashworthy Applications 2079.3 Geometrical and Material Characterisation of the Impact Attenuator 2149.4 Experimental Test 2169.5 Finite Element Analysis and LS-DYNA 2199.6 Comparison between Numerical and Experimental Analysis 2209.7 Investigation of the Optimal Solution 2219.8 Conclusion 224References 224Part Three DAMAGE AND FAILURE10 Fracture and Failure Mechanisms for Different Loading Modes in Unidirectional Carbon Fibre/Epoxy Composites 229Victoria Mollon, Jorge Bonhomme, Jaime Vina and Antonio Arguelles10.1 Introduction 22910.2 Delamination Failure 23010.3 Objectives 23210.4 Experimental Programme 23310.5 Numerical Simulations 24010.6 Fractography 24410.7 Results and Discussion 24410.8 Conclusion 253References 25311 Numerical Simulation of Damages in FRP Laminated Structures under Transverse Quasi-Static or Low-Velocity Impact Loads 257Ning Hu, Ahmed Elmarakbi, Alamusi, Yaolu Liu, Hisao Fukunaga, Satoshi Atobe and Tomonori Watanabe11.1 Introduction 25711.2 Theory 26111.3 Techniques for Overcoming Numerical Instability in Simulation of Delamination Propagation 26711.4 Numerical Examples 27511.5 Conclusion 291References 29112 Building Delamination Fracture Envelope under Mode I/Mode II Loading for FRP Composite Materials 293Othman Al-Khudairi, Homayoun Hadavinia, Eoin Lewis, Barnaby Osborne and Lee S. Bryars12.1 Introduction 29312.2 Experimental Studies 29412.3 Mode I Delamination Testing: Double Cantilever Bending Test Analysis and Results 29612.4 Mode II Delamination Testing: End Notched Flexure Test Analysis and Results 29712.5 Mixed Mode I/II Delamination Testing: Mixed-Mode Bending Test Analysis and Results 30212.6 Fracture Failure Envelope 30612.7 Conclusion 308Nomenclature 309References 309Part Four CASE STUDIES AND DESIGNS13 Metal Matrix Composites for Automotive Applications 313Anthony Macke, Benjamin F. Schultz, Pradeep K. Rohatgi and Nikhil Gupta13.1 Automotive Technologies 31313.2 Reinforcements 32113.3 Automotive Applications 32813.4 Conclusion 342Acknowledgements 343References 34314 Development of a Composite Wheel with Integrated Hub Motor and Requirements on Safety Components in Composite 345Nicole Schweizer and Andreas B¨uter14.1 Introduction 34514.2 Wheels Made from FRPs 34914.3 Development of a Composite Wheel with Integrated Electric Motor 35814.4 Multifunctional Design – Requirements regarding Structural Durability and System Reliability 36414.5 Conclusion 369References 37015 Composite Materials in Automotive Body Panels, Concerning Noise and Vibration 371Peyman Honarmandi15.1 Introduction 37115.2 Composite Materials in Automobile Bodies 37115.3 Multilayer Composite Materials in Noise and Vibration Treatment 37215.4 Case Studies 37315.5 Conclusion 386References 38716 Composite Materials for Automotive Braking Systems 389David C. Barton16.1 Introduction 38916.2 Materials Requirements for Brake Rotors 39016.3 Cast Iron Rotors 39216.4 Carbon Composite Rotors 39316.5 Light Alloy Composite Rotors 39516.6 Evaluation of Composite Disc Materials 39516.7 Surface Engineering of Light Alloy Brake Discs 39816.8 Friction Material 40016.9 Conclusion 402References 40317 Low-Cost Carbon Fibre: Applications, Performance and Cost Models 405Alan Wheatley, David Warren and Sujit Das17.1 Current and Proposed Carbon Fibre Applications 40517.2 Carbon Fibre Polymer Composites: Cost Benefits and Obstacles for Automobiles 40717.3 Performance Modelling 41417.4 Cost Modelling 42717.5 Conclusion 433Acknowledgements 433References 433Index 435