Damage and Failure Modeling of Composite Material Structures Using the Pam-Crash Code

Simulating composite material structures requires complex constitutive models, which normally require fine meshes to obtain an accurate prediction of their behavior. Pam-Crash software has been used for several years in the automotive industry and has been proved to be an efficient tool for simulating metallic structures, returning good correlations in a fast computational time. However, constitutive models for composite materials in Pam-Crash present some difficulties: some materials are not able to be suitably modeled and the predictive results depend on the mesh refinement. This work proposes a solution for predicting the progressive damage of composite materials in Pam-Crash, which scales the energy dissipated by the damage mechanisms and checks the viability of modeling the material behavior, taking into account the recommended size of finite elements in the automotive industry. The proposed solution is applied for the simulation of Open Hole specimens to evaluate the ultimate strength consistency. After this, it is applied for the simulation of Compact Tension specimens to check the consistency of crack propagation behavior. By considering the target size of the finite elements in the material card definition, the predictions demonstrate great improvement in the equivalence in results between different mesh refinements. Finally, the solution is applied to simulate impact tests on large structures. Good correlations with experimental data are obtained in fast computational times, making this methodology a candidate for application in composite-related automotive simulations.