DYCOMP - ECCCS – 3 2024

Enhancing the crashworthiness in thin-walled filament-wound tubes

  • Scalici, Tommaso (Università degli Studi di Enna “Kore”)
  • Tumino, Davide (Università degli Studi di Enna “Kore”)
  • Alaimo, Andrea (Università degli Studi di Enna “Kore”)
  • Catalanotti, Giuseppe (Università degli Studi di Enna “Kore”)

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In contrast to metal structures, where impact energy is absorbed through plastic deformation, fiber-reinforced composites work differently. These materials don't undergo plastic deformation; instead, impact energy is dissipated by creating crack surfaces due to fiber and matrix fractures, fiber pull-out, debonding, and delamination. Using fiber-reinforced polymers (FRPs) in structures designed for crushing can be challenging. Their behaviour depends on various factors like stacking sequences, matrix and fiber properties, and geometry . Nevertheless, with proper design, composites can achieve higher energy absorption capacity compared to metals. To achieve the desired progressive crushing, which results in significant deceleration during impact and reduces the peak crush load, structures typically incorporate initiators. In composite tubes, researchers often use an edge chamfer as a triggering mechanism . However, studies have produced mixed results regarding the impact of trigger geometry on the Specific Energy Absorption (SEA) during dynamic crushing . This work aims to propose a new approach based on the material architecture of tubular crushing structures, using a composite-composite concept to overcome the dependency of crushing behaviour on triggers and enhance the crushing properties. To control the material architecture during the manufacturing process, different methods like fiber placement or pultrusion may be considered. However, given the tubular shape of the crushing structures and the intended application, filament winding was chosen as the preferred process. To this end, a desktop filament winder was designed and built to produce thin-walled tubes. Cylindrical samples were tested under axial compression, and the resulting failure mechanisms were observed.