Dynamic Axial Crush of Automotive Rail-Sized Composite Tubes Part 1: Tubes with Woven Reinforcements (Carbon, Kevlar?, and Glass) and Non-Plug Crush Initiators

摘要

This paper documents the woven fabric reinforcement portion of a study of the dynamic axial crushof automotive rail-sized composite tubes. Woven reinforcements, ten in all, were comprisedprincipally of carbon fiber but also of Kevlar? and E-glass. Tubes were manufactured using ResinTransfer Molding (RTM) with processing and molding techniques that are suitable for the low costhigh volume needs of the automotive industry. Tubes had a 88.9x88.9 mm square cross section with2.54 mm thick walls. A 45° bevel on the outside edge of the lead end of each tube served as the crushinitiator. For almost all parameter configurations, the tubes exhibited stable and progressive crushwith a reasonably flat plateau force level and a crush initiation force that can be withstood by thevehicle's backup structure. Additionally, crush debris from such tubes was found to neither containobjectionable sharp brittle splinters nor pose a health risk.