Srdan Simunovic

Energy Absorption in Polymer Composites for Automotive Crashworthiness

The energy absorption capability of a composite material is critical to developing improved human safety in an automotive crash. Energy absorption is dependent on many parameters like fiber type, matrix type, fiber architecture, specimen geometry, processing conditions, fiber volume fraction, and testing speed. Changes in these parameters can cause subsequent changes in the specific energy absorption (ES) of composite materials up to a factor of 2. This paper is a detailed review of the energy absorption characteristics in polymer composite materials. An attempt is made to draw together and categorize the work done in the field of composite energy absorption that has been published in the literature in order to better understand the effect of a particular parameter on the energy absorption capability of composite materials. A description of the various test methodologies and crushing modes in composite tubes is also presented. Finally, this paper raises certain design issues by examining the work rate decay necessary to keep the deceleration below 20g during an impact crash.

Crack roughness and avalanche precursors in the random fuse model.

We analyze the scaling of the crack roughness and of avalanche precursors in the two-dimensional random fuse model by numerical simulations, employing large system sizes and extensive sample averaging. We find that the crack roughness exhibits anomalous scaling, as recently observed in experiments. The roughness exponents (zeta, zeta(loc) ) and the global width distributions are found to be universal with respect to the lattice geometry. Failure is preceded by avalanche precursors whose distribution follows a power law up to a cutoff size. While the characteristic avalanche size scales as s(0) approximately L(D) , with a universal fractal dimension D , the distribution exponent tau differs slightly for triangular and diamond lattices and, in both cases, it is larger than the mean-field (fiber bundle) value tau=5/2 .

Statistical properties of fracture in a random spring model

Using large-scale numerical simulations, we analyze the statistical properties of fracture in the two-dimensional random spring model and compare it with its scalar counterpart: the random fuse model. We first consider the process of crack localization measuring the evolution of damage as the external load is raised. We find that, as in the fuse model, damage is initially uniform and localizes at peak load. Scaling laws for the damage density, fracture strength, and avalanche distributions follow with slight variations the behavior observed in the random fuse model. We thus conclude that scalar models provide a faithful representation of the fracture properties of disordered systems.

Frictional contact formulation using quadratic programming

A new solution procedure for contact problems in elasticity with prescribed normal tractions on contact surface has been proposed in this paper. The procedure is based on the boundary element method and quadratic programming. It is next used in a two step solution algorithm for the analysis of contact problems with friction. Several numerical examples are presented and compared with results obtained using alternative solution methods.

Steel Processing Effects on Impact Deformation of UltraLight Steel Auto Body

The objective of the research presented in this paper was to assess the influence of stamping process on crash response of UltraLight Steel Auto Body (ULSAB) [1] vehicle. Considered forming effects included thickness variations and plastic strain hardening imparted in the part forming process. The as-formed thickness and plastic strain for front crash parts were used as input data for vehicle crash analysis. Differences in structural performance between crash models with and without forming data were analyzed in order to determine the effects and feasibility of integration of forming processes and crash models.

Material Modeling Effects on Impact Deformation of Ultralight Steel Auto Body

This paper describes the results of the computational analysis of UltraLight Steel Auto Body (ULSAB) crash simulations that were performed using advanced material modeling techniques. The effects of strain-rate sensitivity on a high strength steel intensive vehicle was analyzed. Frontal and frontal offset crash scenarios were used in a finite element parametric study of the ULSAB body structure. Comparisons are made between the crash results using the piece-wise-linear isotropic plasticity strain-rate dependent material model, and the isotropic plasticity material model based on quasi-static properties. The simulation results show the importance of advanced material modeling techniques for vehicle crash simulations due to strain-rate sensitivity and rapid hardening characteristics of advanced high strength steels. Material substitution was investigated for the main frontal crush structure using the material of similar yield stress a significantly different strain-rate and hardening characteristics.

Modeling of Strain Rate Effects in Automotive Impact

This paper deals with the effects of various approaches for modeling of strain rate effects for mild and high strength steels (HSS) on impact simulations. The material modeling is discussed in the context of the finite element method (FEM) modeling of progressive crush of energy absorbing automotive components. The characteristics of piecewise linear plasticity strain rate dependent material model are analyzed and various submodels for modeling of impact response of steel structures are investigated. The paper reports on the ranges of strains and strain rates that are calculated in typical FEM models for tube crush and their dependence on the material modeling approaches employed. The models are compared to the experimental results from drop tower tests.

Fracture roughness in three-dimensional beam lattice systems.

We study the scaling of three-dimensional crack roughness using large-scale beam lattice systems. Our results for prenotched samples indicate that the crack surface is statistically isotropic, with the implication that experimental findings of anisotropy of fracture surface roughness in directions parallel and perpendicular to crack propagation is not due to the scalar or vectorial elasticity of the model. In contrast to scalar fuse lattices, beam lattice systems do not exhibit anomalous scaling or an extra dependence of roughness on system size. The local and global roughness exponents (ζ(loc) and ζ, respectively) are equal to each other, and the three-dimensional crack roughness exponent is estimated to be ζ(loc)=ζ=0.48±0.03 . This closely matches the roughness exponent observed outside the fracture process zone. The probability density distribution p[Δh(ℓ)] of the height differences Δh(ℓ)=[h(x+ℓ)-h(x)] of the crack profile follows a Gaussian distribution, in agreement with experimental results.

Crack roughness in the two-dimensional random threshold beam model

We study the scaling of two-dimensional crack roughness using large scale beam lattice systems. Our results indicate that the crack roughness obtained using beam lattice systems does not exhibit anomalous scaling in sharp contrast to the simulation results obtained using scalar fuse lattices. The local and global roughness exponents (zetaloc and zeta, respectively) are equal to each other, and the two-dimensional crack roughness exponent is estimated to be zetaloc = zeta = 0.64+/-0.02 . Removal of overhangs (jumps) in the crack profiles eliminates even the minute differences between the local and global roughness exponents. Furthermore, removing these jumps in the crack profile completely eliminates the multiscaling observed in other studies. We find that the probability density distribution p[Deltah(l)] of the height differences Deltah(l)=[h(x+l)-h(x)] of the crack profile obtained after removing the jumps in the profiles follows a Gaussian distribution even for small window sizes (l) .

Test Methodologies for Determining Energy Absorbing Mechanisms of Automotive Composite Material Systems

To identify and quantify the energy absorbing mechanisms in automotive composite material systems, test methodologies were developed for conducting progressive crush tests on composite specimens that have simplified test geometries. The test method development focused on isolating the damage modes associated with the frond formation that occurs in dynamic testing of composite tubes. A new test fixture was designed to progressively crush composite plate specimens under quasi-static test conditions. Preliminary results are presented under a sufficient set of test conditions to validate the operation of the test fixture. The experimental data, in conjunction with test observations, will be used in future work to identify the characteristic damage and failure modes, and determine the specific energy absorption capability of candidate automotive composite material systems.