Frames made of polymer composites are increasingly used in the aerospace, automotive, and agricultural industries. A frequently used technology in the production line of composite frames is winding rovings onto a non-load-bearing frame to form the structure using an industrial robot and a winding head, which is solidified through a subsequent heat-treatment pressure process. In this technology, the most difficult procedure is the winding of the curved parts of a composite frame. The primary concern is to ensure the proper winding angles, minimize the gaps and overlaps, and ensure the homogeneity of the wound layers. In practice, the curved frame parts very often geometrically form sections of a torus. In this work, the difficulty of achieving a uniform winding of toroidal parts is described and quantified. It is shown that attaining the required winding quality depends significantly on the geometrical parameters of the torus in question. A mathematical model with a detailed procedure describing how to determine the number of rovings of a given width on toroidal parts is presented. The results of this work are illustrated with practical examples of today's industrial problems.

• Keywords
• curved composite frame, optimized winding procedure, roving winding, straight helix, toroidal helix, torus, winding angle,
• Publication type
• Journal Article MeSH

The enhancement of fuel economy and the emission of greenhouse gases are the key growing challenges around the globe that drive automobile manufacturers to produce lightweight vehicles. Additionally, the reduction in the weight of the vehicle could contribute to its recyclability and performance (for example crashworthiness and impact resistance). One of the strategies is to develop high-performance lightweight materials by the replacement of conventional materials such as steel and cast iron with lightweight materials. The lightweight composite which is commonly referred to as fiber-reinforced plastics (FRP) composite is one of the lightweight materials to achieve fuel efficiency and the reduction of CO2 emission. However, the damage of FRP composite under impact loading is one of the critical factors which affects its structural application. The bumper beam plays a key role in bearing sudden impact during a collision. Polymer composite materials have been abundantly used in a variety of applications such as transportation industries. The main thrust of the present paper deals with the use of high-strength glass fibers as the reinforcing member in the polymer composite to develop a car bumper beam. The mechanical performance and manufacturing techniques are discussed. Based on the literature studies, glass fiber-reinforced composite (GRP) provides more promise in the automotive industry compared to conventional materials such as car bumper beams.

• Keywords
• automotive bumper beam, glass fiber, impact energy: energy absorption, mechanical design, polymer matrix,
• Publication type
• Journal Article MeSH
• Review MeSH

As a light structure, composite sandwich panels are distinguished by their significant bending stiffness that is rapidly used in the manufacture of aircraft bodies. This study focuses on the mechanical behaviour of through-thickness polymer, pin-reinforced foam core sandwich panels subjected to indentation and low impact loading. Experimental and computational approaches are used to study the global and internal behaviour of the sandwich panel. The samples for experimental testing were made from glass/polyester laminates as the face sheets and polyurethane foam as the foam core. To further reinforce the samples against bending, different sizes of polymeric pins were implemented on the sandwich panels. The sandwich panel was fabricated using the vacuum infusion process. Using the experimental data, a finite element model of the sample was generated in LS-DYNA software, and the effect of pin size and loading rate were examined. Results of the simulation were validated through a proper prediction compared to the test data. The results of the study show that using polymeric pins, the flexural strength of the panel significantly increased under impact loading. In addition, the impact resistance of the pin-reinforced foam core panel increased up to 20%. Moreover, the size of pins has a significant influence on the flexural behaviour while the sample was under a moderate strain rate. To design an optimum pin-reinforced sandwich panel a "design of experiment model" was generated to predict energy absorption and the maximum peak load of proposed sandwich panels. The best design of the panel is recommended with 1.8 mm face sheet thickness and 5 mm pins diameter.

• Keywords
• composite panel, energy absorption, finite element model, low impact loading, pin-reinforced sandwich panel,
• Publication type
• Journal Article MeSH

The stiffness response or load-deformation/displacement behavior is the most important mechanical behavior that frequently being utilized for validation of the mathematical-physical models representing the mechanical behavior of solid objects in numerical method, compared to actual experimental data. This numerical study aims to investigate the linear-nonlinear stiffness behavior of carbon fiber-reinforced polymer (CFRP) composites at material and structural levels, and its dependency to the sets of individual/group elastic and damage model parameters. In this regard, a validated constitutive damage model, elastic-damage properties as reference data, and simulation process, that account for elastic, yielding, and damage evolution, are considered in the finite element model development process. The linear-nonlinear stiffness responses of four cases are examined, including a unidirectional CFRP composite laminate (material level) under tensile load, and also three multidirectional composite structures under flexural loads. The result indicated a direct dependency of the stiffness response at the material level to the elastic properties. However, the stiffness behavior of the composite structures depends both on the structural configuration, geometry, lay-ups as well as the mechanical properties of the CFRP composite. The value of maximum reaction force and displacement of the composite structures, as well as the nonlinear response of the structures are highly dependent not only to the mechanical properties, but also to the geometry and the configuration of the structures.

• Keywords
• CFRP composites, damage mechanics, finite element method, material behavior, stiffness response, structural analysis,
• Publication type
• Journal Article MeSH