INNOVATIVE DESIGN OF A COMPOSITE SIDE DOOR: CRASHWORTHINESS EVALUATION AND DUMMY RESPONSE

This paper addresses the method of analysis and crashworthiness design aspects that should be used with particular reference to the application of composite material to automotive front lateral door design. Starting from an already existing design of the front lateral door, made with traditional mild steel, an alternative innovative solution has been developed, using the potentialities of composite material carbon fiber reinforced plastic-CFS003/LTM25. The innovative solution has been checked against the crash normative requirements. This subject is particularly challenging due to the very small space that is available for the side structure of the vehicle to be devoted to energy absorption. Finite element tool LS-DYNA is used to develop the numerical model of side impact event based on regulation FMVSS 214. The biomechanical response of the side dummy is also evaluated and compared with the limit values reported in the normative. Finally, the obtained results put in evidence that a properly designed composite door could be better of the existing one from the point of view of occupant protection during car side crash impact, with a decrement of the total weight of about, 1,75 kg, i.e. about 9% of the whole steel reference door structure