Browse Publications Technical Papers 2019-01-1100
2019-04-02

Simulation and Experimental Study on Crashworthiness of CFRP Body Electric Vehicle 2019-01-1100

Carbon fiber reinforced plastic (CFRP) composite materials typically have a high strength-to-weight ratio, which is the one of excellent solutions to develop the next generation of lightweight vehicles in automotive engineering, especially for electric vehicles. However, the process of acquiring mechanics properties under quasi-static and dynamic loading, construction of the constitutive model, building and validating crashworthiness model of CFRP materials remain research worthiness. The purpose of this study is to establish the passive safety model, connection, analysis and related methods of CFRP materials body, and to understand its crashworthiness. Based on the explicit numerical algorithm of LS-DYNA, the composite constitutive model *MAT_54 and adhesive constitutive model *MAT_169 are chosen. Three different models of CFRP and adhesive materials are constructed by simple piece test, then a simulation model of battery electric vehicle crashworthiness is built with CFRP composite material body, aluminum alloy frame, wheel hub motor and power battery, steel closures, chassis. The research focuses on the modeling method of zone, lay-up, overlap joint and adhesion. To give a proof of practicability, crash test (front sled crash, 30km/h and rear crash sled, 32km/h) and roof-pressure test of the electric vehicle are conducted. It is found that the result of the simulation test is in good agreement with that of physical test (more than 80% correlation), which indicates that the simulation methods have a great potential in crashworthiness analysis and optimization for CFRP electric vehicle.

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