Optimised composite crash structure development with focus of life cycle analysis for a fuel cell electric vehicle

Abstract

Copyright © 2022 Jayasree et al.. Low-speed accidents see a year-on-year increase. To improve crash performance in these accidents, a crash box is attached between the vehicle bumper structure and the side rail. The determination of the crash box material and geometry is critical to absorb the impact energy to result in safer vehicles and minimised repair costs. As the automotive industry transitions to more sustainable platforms, it is seeking to use lightweight materials including in the crash structure. This study develops an innovative crash box with optimal impact energy-absorption capabilities for a fuel cell electric vehicle. The concept is based on topology optimisation considering the composite structure and crash energy dissipation. In further work, the results from the life cycle analysis are utilised, and a comparative study between carbon fibre reinforced polymers and biocomposites in crash structures is performed. The latter includes an extensive characterisation campaign under static and dynamic conditions. Keywords: Composites; crash box;