ARRK Engineering (Munich, Germany) collaborated with Mitsui Chemicals to explore advanced simulation techniques for an automotive front bumper beam incorporating the TAFNEX™ Structural Sheet and EDX 4030, a long glass PP Compound grade from Mitsui Prime ACE . A key challenge in designing safety-critical components is the accurate prediction of delamination in composite materials, as this failure mode can significantly compromise structural integrity. Conventional finite element modeling (FEM), which typically represents components as shell elements without thickness, is insufficient for capturing delamination behavior. To address this, ARRK Engineering applied a reduced stacked shell modeling approach.
To validate the simulation methodology and optimize both the model and the component design, physical prototypes were manufactured and tested. These tests enabled a precise correlation between simulated and actual delamination behavior, confirming the reliability of the predictive model and supporting further structural optimization.
As part of Mitsui Chemicals’ integrated service offering, the following support was provided:
- Provision of sample materials
- Comprehensive material testing
- Prototyping
- Simulation services
This validated modeling approach enables OEMs and Tier 1 suppliers to accelerate development cycles, reduce prototyping costs, and improve crash performance of lightweight composite structures. The close collaboration between simulation experts and material developers ensured a seamless integration of material behavior into predictive models, bridging the gap between virtual design and physical performance.
Compared to conventional stacked shell models, the reduced approach achieved comparable accuracy with significantly lower computational cost, making it viable for full vehicle simulations. Beyond bumper beams, this methodology is applicable to other structural components in automotive and aerospace sectors where delamination is a critical failure mode.
For detailed technical insights into the modeling approach and simulation methodology, please refer to the CompositesWorld article: “Optimized approach to predict delamination failure in CFRTP structures” (Published July 24, 2023).
Mitsui Chemicals and ARRK Engineering look forward to future collaborations and component evaluations using TAFNEX™ CF-PP UD, supporting the industry’s transition toward more sustainable and efficient mobility solutions.
