A novel method of tube manufacture for vehicle crashworthiness utilising the QUICKSTEP™ Process.

A novel method of composite tube manufacture was developed for potential use in automotive crash structures. Tubes were crushed axially under quasi-static conditions and highly repeatable behaviour was observed with an average specific energy absorption of -85kJ/kg. DMTA results indicated that the tubes were fully cured, even when the cycle was reduced to 7 minutes, giving this process huge potential for high-volume production.

Development of material models to predict the crashworthiness of tubes

Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to produce light weight yet safer vehicles has led to the need to understand the behaviour of novel materials such as composites, metallic foams and sandwich structures durign a crash. This paper presents a method to predict the crashworthiness of structural components using material modes. The material factors that most affect the crushing response are determined and quantified by developing and validating the crushing of a square tube model in Abaqus. The inputs from the model are used to construct a simple, physically realistic constitutive model and new test methods for predicting the material behaviour at high strain rates using low test speeds. These material models enable a designer to predict the crash behaviour of a structure without the need to perform extensive physical tests, thus reducing the time and cost of development.

Finite element modelling of metallic tubular crash structures with an explicit code

Numerous experimental studies have been carried out to investigate the collapse of tubular metallic crash structures under axial compression. Some simple theoretical models have been developed but these often assume one type of progressive collapse, which is not always representative of the real situation. Finite Element (FE) models, when further refined, have the potential to predict the actual collapse mode and how it influences the load-displacement and energy absorption characteristics. This paper describes an FE modelling investigation with the explicit code LS−DYNA. An automatic mesh generation programme written by the authors is used to set up shell and solid element tube models. Mesh specification issues and features relating to the contact and friction models are discussed in detail. The crush modes, load-deflection characteristics and energy absorption values found in the simulations are compared with a reasonable degree of correlation to those observed in a physical testing programme; however, improvements are still required.

Rapid composite tube manufacture utilizing the quickstep™ process

In this study, a novel method for manufacturing composite tubes utilizing the Quickstep^TM process has been developed. Tubes manufactured from `quick-cure' Toray G83C prepreg have demonstrated highly repeatable axial crush behavior with an average specific energy absorption (SEA) of 86 kJ/kg. The cure cycle is optimized by comparing the results from compression, dynamic mechanical thermal analysis (DMTA), differential scanning calorimetry (DSC), and porosity testing. The tube lay-up is optimized using compression and porosity test results. The effect of changes in fiber-orientation on SEA is also investigated. Process development has resulted in a robust manufacturing method capable of producing fully cured, high performance composite tubes with a cure cycle of 7 min. This corresponds to a 95% reduction in time compared to an equivalent autoclave cycle.

Compressive properties and energy absorption of hollow sphere aluminium

Manufactured cellular aluminums have been developed for a wide range of automotive applications where weight savings, improved safety, crashworthiness and comfort are required. The plateau deformation behavior of cellular aluminums under compressive loading makes this new class of lightweight materials suitable for energy absorption and comes close to ideal impact absorbers. In the present study, aluminum hollow hemispheres were firstly processed by pressing. Hollow sphere aluminum samples with a body-centered cubic (BCC) packing were then fabricated by bonding together single hollow spheres, which were prepared by adhering together hollow hemispheres. Hollow sphere aluminum samples with various kinds of sphere wall thicknesses of 0.1 mm, 0.3 mm and 0.5 mm but the same outside diameter of 4 mm were investigated by compressive tests. The effects of the sphere wall thickness on the mechanical properties and energy absorption characteristics were investigated.

Testing and modelling to obtain material behaviour for crash simulations

The thesis focusses on improving the material behaviour models used in vehicle crash simulations by identifying the mechanical properties most important to crash events, reformulating the material models used in crash simulations, and developing new tests to obtain crash-relevant material.

Composite crashworthy structures

This study presents an innovative finite element delamination model which successfully reproduced the experimental failure behaviour observed in axial crush testing. Tests were conducted on tubes manufactured by a novel composite curing process, resulting in the ability to cure tubular profiles in 7 minutes - 95% quicker than traditional autoclave curing.

Vehicle design for minimum societal harm

A design technique was developed to provide the best protection to all occupants in the real-world crashes that occur on Australian roads. A team of experts from around the world was marshalled to analyse crash data, develop new information on impact injury and a new computer optimising technique for simulation of side impact crashes.

Processing of fine-grained aluminum foam by spark plasma sintering

Porous materials are now becoming attractive to researchers interested in both scientific and industrial applications due to their unique combinations of physical, mechanical, thermal, electrical and acoustic properties in conjunction with excellent energy absorption characteristics. Metallic foams allow efficient conversion of impact energy into deformation work, which has led to increasing applications in energy absorption devices. In particular, foams made of aluminum and its alloys are of special interest because they can be used as lightweight panels, for energy absorption in crash situations and sound or heat absorbing functions in the automotive industry with the aim to reduce weight to improve crashworthiness, safety and comfort.

Crash investigation of side intrusion beam during high and low pressure tube hydroforming

Advanced high strength steels (AHSS), in particular, are an attractive group materials, offering higher strength for improved energy absorption and the opportunity to reduce weight through the use of thinner gauges. High pressure tube hydroforming (HPTH) has been used to produce safety components for these steels, but it is expensive. Low pressure tube hydroforming (LPTH) is a lower cost alternative to form the safety components in the car. The side intrusion beam is the second most critical part after front rail in the car structure for passenger safety during crash. The forming as well as crash behaviour of a square side intrusion beam from both processes was investigated using numerical simulation. This paper investigated the interaction between the forming and crash response of these materials in order to evaluate their potential for use in vehicle design for crashworthiness. The energy absorption characteristics of the different tubes were calculated and the results from the numerical analyses compared for both hydroforming process.

CAE crash analysis of structures in oblique loading

This work focussed on how tubular steel structures similar to that in frontal car frames deform under crash conditions. The novelty comes from finding three crash modes: axial crush, transitional and global bending. Each mode was categorised by reaction force and energy absorption, this allowing for better structural design practices.

Modelling the side impact of carbon fiber tubes

Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to improve fuel economy and reduce vehicle emissions has led automobile manufacturers to explore the crash properties of light weight materials such as fibre reinforced polymer composites, metallic foams and sandwich structures in order to use them as crash barriers. This paper discusses the response of carbon fibre reinforced polymer (CFRP) tubes and their failure mechanisms during side impact. The energy absorption of CFRP tubes is compared to similar Aluminium tubes. The response of the CFRP tubes during impact was modelled using Abaqus finite element software with a composite fabric material model. The material inputs were given based on standard tension and compression test results and the in-plane damage was defined based on cyclic shear tests. The failure modes and energy absorption observed during the tests were well represented by the finite element model.

The indentation behaviour of carbon fibre composite tubes-experiments & modelling

Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to produce lighter weight, yet safer vehicles has led to the need to understand the crash behaviour of novel materials, such as fibre reinforced polymer composites, metallic foams and sandwich structures. This paper discusses the static indentation response of Carbon Fibre Reinforced Polymer (CFRP) tubes. The side impact on a CFRP tube involves various failure mechanisms. This paper highlights these mechanisms and compares the energy absorption of CFRP tubes with similar Aluminium tubes. The response of the CFRP tubes during bending was modelled using ABAQUS finite element software with a composite fabric material model. The material inputs were given based on standard tension and compression test results and the in-plane damage was defined based on cyclic shear tests. The failure modes and energy absorption observed during the tests were well represented by the finite element model.

Occupational light vehicle use: characterising the at-risk population

Previous occupational light vehicle research has concentrated on employees using cars. The aim of this study was to identify and characterise the total occupational light vehicle-user population and compare it with the privately-used light vehicle population. Occupational light vehicle and private light vehicle populations were identified through use-related 2003 registration categories from New South Wales Roads and Traffic Authority data. Key groups of occupational light vehicle registration variables were comparatively assessed as potential determinants of occupational light vehicleuser risks. These comparisons were expressed as odds ratios with 95% Confidence Intervals. The occupational light vehicle population vehicles (n=646,201) comprised 18% of all light vehicle registrations. A number of statistical differences emerge between the two populations. For instance, 86% of occupational light vehicle registrants were male versus 65% of private registrants, and 56% of the occupational users registered load shape vehicles versus 20% of the private registrants. Occupational light vehicles registered for farming or taxi use were more than six times more likely to belong to sole-traders than organisations. Sole-traders were nearly twice as likely to register light-trucks, and twice as likely to register older vehicles, than organisations. This study demonstrates that the occupational light vehicle user population is larger and more diverse than previously shown with characteristics likely to increase the relative risks of motor vehicle crashes. More occupational light vehicles were load shapes and therefore likely to have poorer crashworthiness ratings than cars. Occupational light vehicles are frequently used by sole-traders for activities with increased OHS risks including farming and taxi use. Further exploration of occupational light vehicle-user crash risks should include all vehicle types, work arrangements and small ‘fleets’.

Energy absorption behaviour of rapidly manufactured carbon/epoxy and glass/polypropylene structures

In this thesis the crashworthiness of composite tubular structures was investigated along with the property structure relationships of a glass/polypropylene material. The energy absorption capacity of tubular structures in a number of different testing configurations was made. Two materials; carbon/epoxy pre-preg and a glass/polypropylene dry pre-preg were investigated.