Methodology to simulate veneer based structural components for static and crash load cases

Abstract

The increased public interest in green technology combined with new environmental policies results in the need for light-weight vehicles with a reduced global environmental impact. A method that is gaining importance is the reduction of the cradle-to-grave carbon footprint of utilized materials. For structural components, one promising approach is the utilization of biomaterials such as veneer-based hybrid materials since wood is a natural carbon storage. The specific properties of wood are comparable to aluminum and magnesium, and thus have the potential to replace some structural and semi-structural components of a vehicle. When required, the hybridization of veneer-based materials with traditional materials, such as metal sheets, can further increase its structural performance. While it is technologically possible to implement such a material concept, a key challenge is the application-oriented simulation of non-hybridized and hybridized wooden structures. A suitable simulation method and material model must be found and validated. At the Institute of Vehicle Concepts of the German Aerospace Center, the methodology to simulate beech-veneer based structural components for static and crash load cases has been developed over the last three years. The characteristics of the veneer were determined in order to fit a material model in LS-Dyna which was then implemented in various simulation approaches for wooden structures. The findings were also transferred to simulate hybridized structures. This paper presents the chosen approach to simulate a hybridized generic structure that represents a door impact beam. It compares simulation results of different three-point flexural bending tests with testing results. The findings were generated in the project For(s)tschritt. The fully qualified simulation approach and material model will contribute to the structural application of non-hybridized and hybridized veneer-based composites in modern vehicle structures.