Simulation of the Crash Performance of Crash Boxes based on Advanced Thermoplastic Composite

Because of their superior mechanical properties in combination with a relative low density Fiber Reinforced Composites (FRC) are of great potential in the area of lightweight structures respectively applications. Consequently FRC is gaining influence and acceptance not only in the automotive industry. Unfortunately the application of endless reinforced composites with duroplastic matrix was mainly restricted by a production technique unsuitable for a full production run. Up to date it was only possible for short and long fiber reinforced duroplastic SMC (Sheet Molding Compound) and thermoplastic GMT (Glass Mat Reinforced Thermoplastic). Compared with conventional reinforced duroplastics the continuous reinforced thermoplastic composites (Advanced Thermoplastic Composites) have the capability for a full production run in terms of a thermoforming procedure (see Figure). With this technique Jacob Composite and partners were able for the first time to deliver fiber reinforced composite bumper beams in a number of 50.000 pieces/year for the automotive industry.