Overview
The prediction and optimisation of the crash behaviour of mass produced fibre reinforced polymer (FRP) composite structures with regard to alternatively powered vehicles (APV) is in the focus of the MATISSE project. The ability to investigate crashworthiness of FRP vehicle structures by numerical simulation is crucial for these lightweight materials to see widespread use in future cars. By delivering this ability, MATISSE will lead to safer, more efficient and more desirable cars.
MATISSE aims to take a significant step forward in the capability of the automotive industry to model, predict and optimise the crash behaviour of mass produced Fibre Reinforced Polymer (FRP) composite structures, which will be extensively used in Alternatively Powered Vehicles.
With a consortium led by the automotive industry, but also including partners active in the aerospace domain (where FRP structures are widely used), MATISSE will leverage the knowledge from the aeronautical sector while assuring that advances in modelling, simulation and testing capabilities will be directly applicable to and acceptable for automotive applications, reinforcing the European automotive sector.
To validate the modelling and simulation approach and demonstrate its impact on vehicle design - we propose to use our improved methods for the investigation, design and testing of two important safety-critical parts of future APV. Both parts are examples of pressurised structures:
- CNG fuel tanks these have high quasi-static internal pressures of 200-250 bar, and the main safety concern is breach of integrity under crash, causing the pressurised contents to escape. Gaseous fuels are highly combustible, so breach of integrity constitutes a severe fire hazard.
- Adaptive crash structures these will be actively pressurised in a crash (comparable to an airbag) to change a structure’s stiffness to protect both occupants and safety critical parts of the vehicle as well as crash partners.
With a consortium focusing on the automotive industry and including partners active in the aerospace domain (where FRP structures are widely used), MATISSE leverages the knowledge from the aeronautical sector while assuring that advances in modelling, simulation and testing capabilities will be directly applicable to and acceptable for automotive applications, reinforcing the European automotive sector.
Funding
Results
Safe alternative-fuel vehicles
EU-funded scientists are modelling and testing key composite structures in alternatively powered vehicles (APVs). Investigating the crashworthiness of these lightweight materials is crucial to increasing their widespread commercial uptake.
Currently, the ability to model, simulate and predict the behaviour of fibre-reinforced polymer structures lags way behind compared to pressed-steel car bodies. To address this issue, scientists initiated the EU-funded project http://www.project-matisse.eu/ (MATISSE).
The project is developing and testing modelling techniques for fabric-reinforced structures and thick composites with unidirectional fibres. To validate the modelling approach, focus is placed on designing and testing two important safety-critical parts of future APVs, both being examples of pressurised structures. These are compressed natural gas (CNG) fuel tanks and adaptive crash structures.
By using finite element models, scientists are producing designs for lighter and safer cars with on-board high-pressure storage tanks that are subject to dynamic loading. Work is also geared towards designing and assessing adaptive inflators for pressurising adaptive crash structures. Different pressurisation concepts are explored not only to improve the structure stability in case of crash, but also to provide reduced mass and higher packaging efficiency.
So far, scientists have analysed the most likely crash scenarios to find suitable locations for applying composite structures. A testing methodology for identifying the main load paths on the fuel tank in case of a crash has been defined. CNG vehicles are expected to withstand the forces exerted on the gas cylinder in case of a front, lateral or rear collision, avoiding leakage or fire. Ultimately, making CNG tanks lighter and more tightly integrated into the vehicle not only has environmental benefits, but also increases passenger safety.
Scientists selected a door beam as an application for an adaptive crash structure made of fibre-reinforced composites. Several composite materials have been considered for its design, and the inflating mechanisms have also been produced. Based on these concepts, a prototype beam door has been developed.
MATISSE's ultimate aim is to provide advanced crash modelling tools that should allow automotive designers to adequately simulate and test various safety aspects of APVs. The generated reference designs for adaptive crash structures are also likely to find application in non-APVs.