Sheet Molding Compound Automotive Component Reliability Using a Micromechanical Damage Approach

Abstract

The mastering of product reliability is essential for industrial competitiveness. If for metallic materials the topic is well-known, especially in automotive industry, Original Equipment Manufacturers are expecting strong support of their suppliers to full-fill the lack data. This paper presents a new original approach, using a micromechanical based on damage model to address the problem of reliability of Sheet Molding Compound (SMC) components. The first part demonstrates the inadequacy of the standard method of reliability on SMC material through its application on the new Peugeot 3008. In fact, the very flat S-N curve of SMC, and in general, composite materials is not appropriate for acceleration effect. The proposed model correlates the stress, damage and strength with both cycle number and slamming velocity. It emphasizes the relation between the effective distribution with the slamming velocity effect. Then, a new reliability approach based on a micromechanical fatigue/damage model was developed. The definition of new probability distributions based on damage was necessary to apply properly the stress-resistance approach. It allows taking into account the velocity effect by switching in damage space. Finally, applying this new methodology on the Peugeot 3008, leads to the definition of the optimal validation laboratory tests to ensure the reliability. Indeed, the required number of cycles to ensure reliability has been reduced significantly. Micromechanical damage reliability approach could be an efficient way to ensure the reliability of short fiber reinforcement composite components used in industrial context.