| CRACTAC | This project is closed |
| Crashworthy Automotive Structures using Thermoplastic Composites |
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Context Composite materials are becoming more attractive to the motor industry to occupant and pedestrian protection but remain sufficiently light to reduce fuel consumption. Composites using a thermoset matrix have been used on high performance vehicles for a number of years, but the technology (other than for non-structural appearance panels) has not transferred to large volume, mass market vehicles. This is mainly due to the long cycle times caused by the requirement for in mould cure of the matrix. Thermoplastic matrix composite materials overcome this problem. They are stamp formable and cycle times can be reduced to less than one minute. They offer the weight saving and performance benefits of a composite material, without the cost penalties associated with long cycle times. Being able to process rapidly and predict the behaviour of thermoplastic composites reliably will speed up the design cycle, reducing cost. This will lead to these materials becoming a viable alternative to metals in structural and semi-structural automotive applications. Aims To develop a database of material properties and a predictive model for the impact performance of thermoplastic composite materials and sandwich structures. To develop processing technologies and tooling to manufacture components from these materials. To design and develop structural automotive demonstrator components which can be used to verify the predictive models and demonstrate the viability of novel material combinations and processing technologies Method Undertake research in materials and processing technology and crash modelling to develop automotive demonstrator components. Carry out manufacturing studies and crash modelling work on selected technology demonstrator components. Develop and test a novel tool design allowing both flow-moulding and net shape charges to be co-moulded for optimum performance Investigate and develop processing technologies for foam and honeycomb sandwich structures with thermoplastic composite facings and use FE modelling to predict the behaviour under global flexure and local crushing. Compare bonding techniques to identify the most suitable for an automotive component. Benefits The ability to predict the behaviour of thermoplastic composites and manufacture components to the quality standards demanded by modern automotive manufacturers A database of material properties and a methodology for predictive design as well as an in depth study of the effect of processing on component performance. Weight saving on new vehicles through the use of novel materials. Participants University of Nottingham University of Warwick Advanced Materials and Machines (AMM) Borealis BMW Group Engineering Systems International (ESI) Ford Motor Company Magna Interior Systems Mapleline Motor Industry Research Association (MIRA) Park Hill Textiles Polynorm |
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