Crashworthiness design using novel composite materials and an innovative analytical tool
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Energy absorption structures are ever-increasingly manufactured from carbon fibre reinforced polymer (CFRP) material systems. A number of new material systems have recently been introduced in the transportation sector, including thin-ply CFRPs, as well as more environmentally sustainable alternatives, such as thermoplastics and natural fibre composites (NFCs). There is a noticeable knowledge gap about the energy absorption capabilities of these novel materials. The present work aims to study the crashworthiness performance of these aforementioned alternatives for possible use in transportation crash structures. The most commonly used experimental characterisation methodology for energy absorption is flat coupon crush testing. Among the numerous works present in literature, which have included a variety of coupon and fixture designs, is that recently presented by Vigna et al.~$[1]$, which importantly includes an adjustable unsupported height mechanism. An innovative analytical design tool has also been developed in order to speed up the initial design phase of new composite crash structures. This tool makes use of the experimental coupon energy absorption parameters to calculate an initial laminate layup for a user-defined three-dimensional (3D) structural surface, based on the desired levels of progressive energy absorption. Through an ongoing collaborative project, this work summarises the results of an experimental test campaign of flat crush coupons manufactured from a variety of novel composite material systems, and uses the analytical tool to provide a re-evaluated initial laminate design for a standardised Formula 1 crash structure employing those novel materials.
