Evaluation of an FE Model for the Design of a Complex Thin-Wall CFRP Structure for a Scientific Instrument.

In this paper, the reliability of a finite element (FE) model including carbon-fibre reinforced plastics (CFRPs) is evaluated for a case of a complex thin-wall honeycomb structure designed for a scientific instrument, such as a calorimeter. Mechanical calculations were performed using FE models including CFRPs, which required a specific definition to describe the micro-mechanical behaviour of the orthotropic materials coupled to homogeneous ones. There are well-known commercial software packages used as powerful tools for analyzing structures; however, for complex (many-parts) structures, the models become largely time consuming for both definition and calculation, which limits the appropriate feedback for the structure's design. This study introduces a method to reduce a highly nonlinear model, including CFRPs, into a robust, simplified and realistic FE model capable of describing the deformations of the structure with known uncertainties. Therefore, to calculate the deviations of our model, displacement measurements in a reduced mechanical setup were performed, and then a variety of FE models were studied with the objective to find the simplest model with reliable results. The approach developed in this work leads to concluding that the deformations evaluated, including the uncertainties, were below the actual production tolerances, which makes the proposed model a successful tool for the designing process. Ultimately, this study serves as a future reference for complex projects requiring intensive mechanical evaluations for designing decisions.

Finite Element Simulation for Analysing the Design and Testing of an Energy Absorption System.

It is not uncommon to use profiles to act as energy absorption parts in vehicle safety systems. This work analyses an impact attenuator based on a simple design and discusses the use of a thermoplastic material. We present the design of the impact attenuator and a mechanical test for the prototype. We develop a simulation model using the finite element method and explicit dynamics, and we evaluate the most appropriate mesh size and integration for describing the test results. Finally, we consider the performance of different materials, metallic ones (steel AISI 4310, Aluminium 5083-O) and a thermoplastic foam (IMPAXX500™). This reflects the car industry's interest in using new materials to make high-performance, low-mass energy absorbers. We show the strength of the models when it comes to providing reliable results for large deformations and strong non-linearities, and how they are highly correlated with respect to the test results both in value and behaviour.