This research investigates the role of how Finite Element simulation models reproduced progressively crushed Glass Fiber Reinforced Polymer (GFRP) parts. The proposed work is motivated by the research questions concerning what are the relevant critical modeling strategies that ac
...
This research investigates the role of how Finite Element simulation models reproduced progressively crushed Glass Fiber Reinforced Polymer (GFRP) parts. The proposed work is motivated by the research questions concerning what are the relevant critical modeling strategies that accurately reproduce the behavior of in-plane crushed laminated composite parts with LS-Dyna, how will the simulation model be evaluated following the modeling strategies, and which are the main similarities and dissimilarities among the result of the modeling strategies considered. The research objective is to develop detailed finite element simulation models for axially crushed GFRP composite parts which can represent complex damage modes by a methodical approach in a reasonable time with LS-Dyna explicit. Previous research has shown the necessity to calibrate many parameters with no physical meaning to correctly reproduce crushing. This research addresses these gaps by benchmarking two material models that are not characterized by such effects (*MAT_261, *MAT_262) in comparison with the one characteristic of such behavior, *MAT_54. The most important contribution is to the crashworthiness industry. To date, no research studies were found in the literature covering all the aspects described. This work demonstrates how to deploy such capabilities starting from simple numerical models, to vehicle parts. To illustrate these concepts, the necessary assumptions to create the models and how the parameters were identified have been described while choosing fully integrated shell and thick shell elements. The qualitative and quantitative criteria defined were necessary to systematically evaluate more than 200 simulations in comparison with available experimental data from Daimler AG. The significant findings from the research demonstrate that *MAT_261 and *MAT_262 are not subjected to strain localization phenomena, unlike *MAT_54. The developed set of parameters resulted in a low sensitivity of the *MAT_262 models concerning element size, lay-up or impact energy. Moreover, the research demonstrates that more accurate quantitative results than the current state of the art can be produced with a 5.0 mm element length against the general belief that fine-meshed and mesh convergence studies are required. Contrary to the expectations *MAT_261 demonstrated a low mean force in crushing although sharing the input parameters with *MAT_262 and similar damage laws. The developed models and set of *MAT_262 parameters can be deployed in full vehicle crash simulations with the plug-in possibility to evaluate new design variants. It is concluded that the findings provide support fulfilling the research objective.