Simulation and experimental study on crashworthiness of CFRP body electric vehicle
To be published on April 2, 2019 by SAE International in United States
Carbon fiber reinforced plastic (CFRP) composite materials is advantageous in high strength to weight ratio, which seems to be one of excellent solutions to develop the next generation of lightweight vehicles in automotive engineering, especially for electric vehicles. However, the process to acquire mechanics properties under quasi-static and dynamic loading, construct the constitutive model, build and validate crashworthiness model of CFRP materials remains worthy of research. This study aims to establish the modeling, connection, analysis, and correlation methods of CFRP material vehicle body in passive safety, and understand its crashworthiness performance. Based on the explicit numerical algorithm of LS-DYNA, composite constitutive model *MAT_54 and adhesive constitutive model *MAT_169 have been chosen. Three kinds of CFRP and adhesive materials’ model were constructed by simple piece test, respectively. Then, a Battery Electric vehicle crashworthiness simulation model has been built with CFRP composite material body, aluminum alloy frame, wheel hub motor and power battery, steel closures, chassis, and so on. The research focused on the modeling method of zone, lay-up, overlap joint and adhesion. After that, crash test (front sled crash, 32km/h and rear crash sled, 40km/h) and roof pressure test of the electric vehicle have been conducted. The correlation is upper than 80% by comparison between simulation and physical test, which means the methods can used in crashworthiness analysis and optimization for CFRP electric vehicle.