Dynamic failure and crash simulation of carbon fiber sheet moulding compound (CF-SMC)

Federico Coren,Zoltan Major,Peter Fischer,Christian Ellersdorfer,Daniel Reinbacher,Philipp S Stelzer

doi:10.1007/s41104-021-00078-1

Abstract

Carbon fiber sheet moulding compounds (CF-SMC) are a promising class of materials with the potential to replace aluminium and steel in many structural automotive applications. In this paper, we investigate the use of CF-SMC materials for the realization of a lightweight battery case for electric cars. A limiting factor for a wider structural adoption of CF-SMC has been a difficulty in modelling its mechanical behaviour with a computational effective methodology. In this paper, a novel simulation methodology has been developed, with the aim of enabling the use of FE methods based on shell elements. This is practical for the car industry since they can retain a good fidelity and can also represent damage phenomena. A hybrid material modelling approach has been implemented using phenomenological and simulation-based principles. Data from computer tomography scans were used for micro mechanical simulations to determine stiffness and failure behaviour of the material. Data from static three-point bending tests were then used to determine crack energy values needed for the application of hashing damage criteria. The whole simulation methodology was then evaluated against data coming from both static and dynamic (crash) tests. The simulation results were in good accordance with the experimental data.Graphic abstract

Highlights

This paper focuses on the use of lightweight material for the construction of a battery cases for electric vehicles (Fig. 1)
Carbon fiber sheet molding compounds (CF-SMC) are a class of materials composed of pre-preg chips or bundles of chopped carbon fibers dispersed in a matrix material
FEM simulations of the 3 point bending dynamic loading were performed matching all the test conditions of Table 1

Summary

Introduction

This paper focuses on the use of lightweight material for the construction of a battery cases for electric vehicles (Fig. 1). CF-SMC material possess a unique combination of properties being lightweight, having high strength values, crack resistance and a competitive price. Using this material to replace the aluminium for a battery case, can lead up to 30% weight reduction, while maintaining excellent mechanical properties [6]. In comparison with traditional carbon fiber products, CF-SMC allows for the decoupling of the product quality from the operator ability. This is due to the quasiisotropic nature of the material, as well as the adoption of pressing techniques [5,6,7,8,9]

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