Low Velocity Impact Response of a New Class of Fiber Metal Laminates Consisting of a 3D Fiberglass Fabric Presenter: Zohreh Asaee
Supervisor: Prof. Farid Taheri
Department of Mechanical Engineering, Advanced Composite and Mechanics Laboratory
Project Overview
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2012
Reduce the Weight
INTRODUCTION Why this combination? Each layer has its own unique properties
Magnesium ALLOYS
Proposed Material Layup
The lightest structural metallic alloys. High strength-to-weight ratio. Currently used in several components of modern cars.
Fiberglass 3D Fabric
Fiber-glass Reinforced polymers
Fiberglass
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A Patent was filed on December 2015.
3DFML-4-2/2
The unique configuration of the vertical fibers significantly enhances fabric’s resistance to impact. Under an impact event, the vertical fibers gradually crush, thus damping a great portion of the energy; 3D Fabric
Results The results of our impact tests revealed that 3DFML4-2/2 consisting of two layers of 3D fabric layer 4mm and two layers of magnesium exhibited the highest energy absorption capacity in terms of weight and cost. This is a crucial factor for enhancing the crashworthiness of structure.
3DFML-4-2/3
The impact energy was totally damped by crushing of the vertical fibers No sign of damage on the passenger side!
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3DFML-4
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3DFML-10 3DFML-4-2/3
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3DFML-4-2/2
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3D FML after Impact Test
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Another unique feature of the composites made by this 3D fabric is that the impact shock is totally damped by crushing the vertical fibers of 3D fabric; thus, no dimple or damage is transmitted to the other side of the 3D composite (i.e., the passenger side). Impact Energy normalized by weight (J/gr)
3DFML-4
It is a recently developed fiberglass woven/braided fabric, consisting of two bi-directional woven fabrics, knitted together by vertical braided glass fiber pillars.
Experimental Investigation
Impact Energy normalized by Cost (J/$)
In order to optimize the configuration of the proposed 3DFML, four different configurations were considered, and examined under impact loading conditions. The performance of different configurations were compared with respect to the impact strength, weight and cost.
3D Fabric
Lightweight, excellent specific strength, and robust. More ductile and less expensive than carbon composites. Extensively used in various industries.
Magnesium
Optimization of configuration
Therefore, enhancing the vehicle crashworthiness is essential for protecting passengers’ lives. In this pathway, the main challenge has been maintaining or even reducing the vehicle’s weight; thereby, improving the energy consumption, and addressing the climate change by decreasing emissions of carbon dioxide (CO2). The main Goals of this project is to introduce an innovative hybrid-material configuration for application in vehicle body structure to:
Increase the Crashworthiness
5000
The proposed material is a laminate of two or three thin light-weight magnesium sheets, interleaved with layers of a unique 3D fiberglass and conventional 2D fiberglass fabrics.
3DFML-10
Fatalities
25000
The new innovative material (3D-FML)
Magnesium
serious Injuries
30000
Number of victims in car crashes
The National Highway Traffic Safety Administration’s primary mission is to “save lives, prevent injuries, and reduce economic costs due to road traffic crashes.” Several new technologies have been introduced to automotive industry to lower the number of collisions. Examples are the Electronic Stability Program (ESP), Collision Warning System, Anti-lock Breaking System (ABS), etc. Notwithstanding all efforts for inhibiting car crashes, the statistics reported by the Transport Canada indicate that the number of victims suffering from serious injuries or fatalities is still large, which implies that irrespective of new technologies, many still fall victim to collisions.
3DFML-4
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3DFML-10 3DFML-4-2/3 3DFML-4-2/2
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Damage mode
Computer Simulations
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Damage mode
Conclusions & Future Work The results of this project indicates that the developed hybrid-composite material system can exhibit a significant specific impact energy and is effectively capable of damping the impact energy and thus enhancing passengers’ protection (thus saving lives). Moreover, its light weight is in line with the energy saving and CO2 reduction challenges that auto industry is currently facing. In the next phase of our investigation, we will develop a design chart for the proposed 3DFML and produce automated manufacturing process for the mass production of this novel composite material.
Computer simulations were performed, using the finite element method, to predict the impact response of specimens. By using computational simulations, configuration-related parameters, such as the number and order of the layers, thickness of the magnesium sheet, and 3D fabric, etc. could be optimized based on the desired properties; thus, saving experimental costs and time.
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ACKNOWLEDGMENTS Simulation of an Impact Test using the Finite Element Method
Zohre Assaee (
[email protected])
Financial support for this project was provided by AUTO21, NSERC, predoctoral Killam Scholarship and Amelia Earhart Fellowship. Prof. Farid Taheri (
[email protected])
