Incremental design process for vehicle structural components using thermoplastic-based composites: A simulation-guided approach for door anti-intrusion beams

Abstract

The design of safety-related structural components in automobiles is a critical phase. Most car manufacturers are aiming at reducing vehicle weight considering continuous fiber-reinforced thermoplastics as candidate to replace metal-based structural components. However, this replacement cannot compromise the safety level already achieved by metal-based designs. A good example is the side door anti-intrusion beam, which is a passive safety component to protect the passengers under a lateral impact. This paper presents an incremental design process to achieve a functional side door anti-intrusion beam fully made of glass fiber reinforced thermoplastic conceived to replace metal-based ones. The reader is guided along the design challenges, where the mechanic-based reasons to adapt the part geometry and composite layout are explained in detail. This incremental design process uses a fully FEM-based approach allowing to reach a standard-defined absorbed energy of 1000 J in a lateral collision. From the simulation analysis, it was found that by implementing essential modifications in the beam’s cross-section corrugation, the damage progression can be slowed down leading to an increase of absorbed energy. Additionally, the enhancement of one extra ply in the proper direction solves severe fracture in the clamping area. The final composite design not only performs similarly to its metal-based counterpart, but also considers aspects of production feasibility. This trip along the design process concludes with the production of the simulate-designed component and its effectiveness under lateral impact is demonstrated. To meet the safety regulations, the model is thoroughly validated against the real impact test by analyzing the response in force, intrusion, energy and damage.