Abstract
As a demonstration of the production process of thermoplastic carbon fiber reinforced plastic (CFRTP) parts by press forming, a varying-cross-section beam has been press formed using thermoplastic carbon fiber composite sheets. The shape of a front side member in an automobile has been applied as the formed shape 800mm long, 170mm wide in front, 270mm wide in the rear and 50mm high. Deformation of the fiber during the press forming has been investigated. Inserting sheets with fiber orientations corresponding to the corner line in the varying width part had an effect on the uniformity of the mechanical strength in the formed beam. Two beams are joined to a closed beam and a drop impact test has been carried out. The results showed that the beam has the favorable characteristic that a constant destruction load is maintained from the front to the distance in which the impact energy is absorbed. The constant destruction load depended on the combined strength of the sheets in the press-forming process.
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