This paper studies the possibility of using commercially manufactured carbon fiber reinforced plastic (CFRP) profiles for automotive structural safety applications, especially for side crash. Since cost is one of the main disadvantages limiting large scale use of composites in automobiles, use of commercially manufactured standard profiles of CFRP is proposed. The rocker/sill area in Body in White (BIW) is a very critical load bearing area for side impact. This study aims at understanding the design aspects of CFRP profile to be used as an important load bearing component within the sill/rocker area. Finite element software ANSA is used for FE modeling of the composites. Commercial finite element code, LS-Dyna, is used for the numerical studies of the CFRP profiles. Material model MAT_054 available in LS-Dyna is used for simulating a side crash behavior with CFRP tube. Component level three point bend test is done to compare design variants of CFRP tubes. The type of profile (circular, rectangular etc), dimensions, thickness, stacking sequence and orientation angles are determined by series of simulation studies. Typical load patterns in side impact are considered for the study. Results indicate the possibility of improvement in side impact performance and reduction in weight when using composite tubes. The optimal designs from the studies are proposed to be incorporated into an existing BIW and analyses with full vehicle side impact analysis.

Keywords: CFRP tubes, Side impact, Automobile, Body in white, LS dyna, Simulation.