Finite Element Modeling and Damage-Failure Simulation of Laminated CFRP Components for Vehicle Crash Simulation

A reliable numerical model for composite structures in vehicle crash simulations is needed because passive safety requirements are stricter than ever. The objective of the present study is to evaluate the prediction capability of a finite element (FE) model for bending and axial compression deformations, which are the main modes of vehicle structures in a crash scenario. First, we performed four-point bending simulations of a carbon fiber reinforced polymer (CFRP) laminated component using a multi-layered shell model, where the laminate consists of homogenized plies and interfaces between plies. The continuum damage mechanics (CDM) model is introduced to the intra-ply, and the damage parameters in the longitudinal direction are identified from a crack growth resistance curve (R-curve). The predicted fracture behavior and the force–displacement relationship are in good agreement with the test results. Next, we propose a discrete FE modeling scheme where cohesive elements (CEs) are inserted at all possible crack locations in axial progressive crushing. Because there is no mass loss due to element deletion, it is possible to accurately simulate the load transmission effect. Numerical studies with different laminate configurations reveal that the proposed model can capture the crushing mode under different circumstances.