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Parametric Optimization of Impact Behavior of a Woven Laminate Plaque

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Parametric Optimization of Impact Behavior of a Woven Laminate Plaque Using Ultrasim


The new Corporate Average Fuel Economy (CAFE) standards generate high demands on materials used for lighter vehicle components while maintaining performance targets. Coupled with the need to reduce prototyping cost, accurate prediction and rapid design optimization using Computer-Aided Engineering (CAE) becomes crucial. In composites, the effect of the manufacturing process on the structural performance of the part is often overlooked during the design process, with rule of thumb assumptions often being used. This paper investigates a means of properly accounting for these manufacturing effects on a woven glass laminate in a design optimization for impact performance. The optimization parameters chosen include a representative sample of both processing and design variables. Draping and mold-filling simulations are used to obtain the local fiber orientations, which are used to map the BASF material law to the structural mesh. A falling dart test of the plaque is then simulated, and the design is optimized to maximize failure energy. This loadcase represents the stone-impact requirement for automotive underbody applications, such as oil pans. The mapping process generates an advanced material property that specifies a unique response for every integration point of the structural model based on the processing simulation. Coupled with the internal material testing and fitting performed by BASF, this material model allows highly accurate simulations of anisotropic fiber reinforced composite structures, especially under highly dynamic loads.


Authors: Praphulla Chandra, James McGuire


Conference: CAMX 2016 – Anaheim


SKU/Code: TP16-0138


Pages: 15


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