Challenge

Hybrid composite-metal-structures are often an excellent compromise between low weight and low costs. However, especially the crash dimensioning of such structures is a real challenge. In this project, the task was to assess the potential of new composite-metal-designs for a crash absorber and a sill structure.

Method

Both the vehicle structure and the barrier elements used in the crash tests were modelled in detail and backed with complex material models. Dynamic impact analyses have been performed and material and geometry parameters were gradually optimized until the desired crash behaviour was achieved with minimal use of material.

Result

We enabled the customer to evaluate the potential of the new component designs quickly and without extensive test series and to make a well-founded decision regarding further investments in this technology.