• Document: Validation of Material Models: Development of Carbon Fiber Reinforced Thermoplastic Composites Jeff McHenry Shape Corp Abstract Jeff McHenry, Jian Tao Thermoplastics composites are increas...
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Validation of Material Models: Development of Carbon Fiber Reinforced Thermoplastic Composites Jeff McHenry Shape Corp Abstract Jeff McHenry, Jian Tao Thermoplastics composites are increasingly competing with thermosets because of the advantages these materials offer in terms of short cycle time, good toughness, and recyclability. However, thermoplastic composites, especially those that are reinforced with continuous carbon fibers, still have significant barriers to overcome before they are widely used in large and complex automotive structural components. These include cost, mass production methods, and predicative technique for performance as well as processing. Research has been ongoing under United States Advanced Materials Partnership (USAMP), various consortia and universities to assess and develop this technology. This paper will outline the primary development of carbon fiber weave reinforced Nylon for crush cans in a vehicle front end structure. This is a collaboration effort between FCA, Ford, General Motors and suppliers through the USAMP VMM project and funded by the department of energy (DOE). Low cost carbon fiber developed by ORNL has also been investigated and will be discussed. Agenda:  Background/ introduction of whole project • Thermoplastic objective: Material and process development  Current design of parts  Material selection • Why thermoplastics; advantages (disadvantages); material sources and selection criteria (part needs, design); low cost carbon fiber(film production..), c-ply; comparison data for material selection  Process development • Design requirements, tooling constraints, oven,  Tooling design, molding equipment  Assembly  Material testing  Physical testing  Correlation  Next steps  Acknowledgments Background  Cooperative project with U.S. DOE and USAMP  Validate material models to predict crash performance in carbon fiber composite automotive structures.  Models developed in LS-DYNA, RADIOSS, PAM-CRASH, Abaqus, as well as ACC/USAMP developed models from University of Michigan and Northwestern.  Predictions compared to experimental results from dynamic crash testing of front bumper and crush can systems.  Successful validation of crash models will facilitate improved design of lightweight carbon fiber composites in automotive structures for significant mass savings. Thermoplastic Objective 1. Create carbon composite layup for material testing and CAE card generation.  Identify materials for part construction  Test manufactured part layup construction  Generate material card: MAT_058 for LS-DYNA for each material 2. Manufacture crush cans with thermoplastic carbon composites  Use existing tooling when thermoset run is complete  Manufacture parts with similar layup construction  Trim parts  Adhere can halves  Provide complete assemblies for testing Current Design of Composite FBCC  Design of Thermoset Composite FBCC • Crush cans are 12 QI layers of woven carbon fabric • Bumper beam C-Channel is 24 layers of QI woven carbon fabric • Ribs & crush can back flange are carbon fiber SMC  Design direction set for molding of thermoset carbon crush can and front bumper system • Tooling designed for compression molding of epoxy/CF and SMC • Material layup determined by material testing and simulation  Thermoplastic phase was completed with original compression tooling and similar material makeup *See other USAMP presentations for results of study with thermoset materials Thermoplastic Composites Why use thermoplastic composites? Advantages: Disadvantage: • Rapid forming- Low cycle time • Reduced performance with heat when • Reheat/reform in additional processes compared to thermosets • Joining: Hot plate welding… • Availability of composite prepregs • Toughness • Lower fiber volume content • Easier to recycle How will thermoplastic/carbon fiber compare to similar thermoset crush can on the basis of predictability and performance? Material Selection Criteria  Use of carbon fiber as reinforcement • Specifically continuous fiber for can body: Twill woven (2x2) fiber to mimic thermoset can design • Discontinuous carbon fiber for flanges of crush can  Custom layup and design thickness • QI layup similar to established design •

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