Putting lightweighting to the test

Material laws and orientation information are coupled in a single finite element analysis to predict the performance of the hybrid composite beam under a dynamic three point bending load.

Addressing the transportation industry megatrends to improve fuel efficiency and reduce carbon emissions, lightweight polymer composites are replacing heavier metal counterparts in automotive, aerospace, and commercial vehicle applications. Polymer composites also offer design flexibility, easy fabrication, and parts consolidation. As transportation industry engineers faced with stringent safety requirements and dynamic applications adopt polymer composite solutions, accurate material models are required to predict behavior and failure.

Over-molding continuous fiber reinforced preforms with short glass reinforced polyamide (PA) 6,6 nylon may be used in lightweight door reinforcement beams to protect from side impact. Engineers from DuPont manufactured a demonstration beam by compression molding a woven fabric reinforced nylon sheet, followed by over-molding a short fiber reinforced nylon polymer.