Finite Element Method for Predicting the Behavior of Sandwich Structure Luggage Floor of Passenger Cars

Abstract

Sandwich structures are gaining more importance in automobile industry due to its low weight, high flexural stiffness, and corrosion free properties. The composite structure with paper core sandwiched between two Polypropylene Glass-Filled (PP-GF) faces are being utilized for load floor of luggage compartments in passenger cars. To design, develop, and optimize the luggage floors, reliable Finite element (FE) methods are essential.This study deals with developing a finite-element method to predict the behavior of the luggage floor of a typical Sedan car during ball impact test and static stiffness test. FE simulations are performed using LS-Dyna explicit code. Honeycomb core is modelled using solid elements and Modified honeycomb material model in LS-Dyna is assigned to the honeycomb structure. The two faces, bottom and top, are modelled using shell elements and modified-piecewise linear plasticity material model is assigned to them, respectively.Experimental investigations are done for quasi-static four point bend test. FE simulations are performed for quasi-static four point bend test and validated with experimental results. Based on validated FE method, the ball impact test and static push test are simulated. Experiments are performed for the ball impact test and static push test. The results are compared and correlation between experiment and FE simulation is studied by comparing the deformation pattern, forces, and displacements. This developed FE method is for predicting the behavior of the luggage floor.