On Crashworthiness and Energy-Absorbing Mechanisms of Thick CFRP Structures for Railway Vehicles

This study aims to provide important guidelines for the crashworthiness design of composite energy-absorbing structures, especially railway vehicles. An experimental and numerical investigation was carried out to explore the crushing response of circular composite tubes reinforced with plain woven carbon fiber-reinforced polymers (CFRP). Quasi-static and dynamic axial crushing tests were performed on CFRP tubes with an inner diameter of 100 mm and a nominal wall thickness of 12 mm. Experimental results showed that increasing loading velocity led to a 21.8% reduction in specific energy absorption (from 99.7 kJ/kg to 78.7 kJ/kg) but had negligible influence on failure modes. Finite element models were also established and validated against the experimental results using ABAQUS/Explicit software. The effects of several different parameters such as the number of shell layers, friction coefficient, and interface properties on the simulated results, were also investigated and analyzed. A small variation in these parameters could change the total energy absorption of CFRP tubes. The comparisons between the predicted and experimental results indicated that a finite element model with 10 shell layers could effectively replicate the crushing response. In addition, the simulated results indicated that the damage of tubal wall materials dominated the major energy-absorbing mechanisms of CFRP tubes under quasi-static loads, which was 69.1% of the total energy. The energy dissipated by friction effects between the loading platen and the crushed fronds was 24.1% of the total energy. The increase in the loading velocity led to a decrease in the composite damage energy except for friction energy, resulting in a decrease in the total energy absorption.