Numerical and experimental crashworthiness assessment of carbon-fiber reinforced thermoplastic energy absorbers

A numerical and experimental investigation is carried out in this study to evaluate the crashworthiness behavior, the energy-absorbing parameters, and the failure mode of thermoplastic composite energy absorbers under axial loading. The energy absorbers are thin-walled circular tubes made of woven polyphenylene sulfide carbon composite and have a bevel trigger on the top. Finite element analysis are conducted to predict the structural behavior of the tubes. To validate the numerical model, four specimens are manufactured and tested under an axial compression load. During the tests, the load and displacement are measured by a load cell, the evolution of the longitudinal strains is captured by digital image correlation, and the progression of the failure is recorded by a high speed camera. The tubes show a progressive failure mode, with delamination between the middle plies. A stable damage propagation is observed throughout the tests, where the bevel trigger plays an important role in increasing the stability and failure progression of the thin-walled tubes. The test results are compared to the numerical prediction, with good agreement for both crashworthiness parameters and delamination behavior. The thermoplastic composite energy absorbers achieved specific energy absorption values of up to 70 kJ/kg, indicating an adequate crashworthiness performance.