Mechanism-based modeling of failure and damage in thick multi-layered composite structures

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The use of unidirectionally fiber-reinforced composite (UD FRC) materials in the automotive industry has surged in recent years, primarily due to their advantages over traditional metallic materials. Key benefits include their lightweight nature, low density, high specific modulus, and high specific strength, along with adaptability for specific applications. Their layer-wise processing into laminates allows for complex geometries with varying properties. Additionally, the design of fiber-reinforced composite (FRC) laminates for stiffness and strength is increasingly integrated into efficient, computer-aided engineering processes. This research specifically addresses composites created through filament winding, a technique gaining popularity across various industries, including the production of high-pressure fuel storage tanks for hydrogen-powered vehicles. The study aims to develop impact and crash simulations for next-generation fuel-cell vehicles equipped with high-pressure hydrogen storage vessels made from carbon fiber-reinforced plastic (CFRP). A computer-aided engineering (CAE) process chain is established, encompassing virtual composite vessel generation, three-dimensional explicit finite element analysis using multi-layered solid elements, and a constitutive model. The primary focus is on developing and implementing material equations for CFRP to accurately capture intralaminar failure and post-critical behavior.