Grant: Alliance Grants
University of Waterloo
$189,952.00
Development of safe ultra-lightweight liquid molded composite structures for next-generation electric vehicles
FY 2023-24
Summary
The overarching goal of this research partnership is to support the integration of lightweight liquid molded fiber-reinforced plastic (FRP) composite materials into energy absorbing structures of next-generation electric vehicles (EVs). Current EVs are substantially heavier than gas-powered vehicles due to the immense mass of the battery cells and the fortified suspension and braking systems. A drastic reduction in weight through use of FRP composites will significantly improve the performance of vehicles and extend their driving range from a single charge, while simultaneously improving their crash safety. The proposed research will address a critical need to develop a novel integrated process-performance simulation platform to accurately predict the impact performance of as-manufactured lightweight high-pressure resin transfer molding (HP-RTM) FRP composite structures to support the design and fabrication of a new frontal crash component. Several key scientific challenges associated with rapid HP-RTM of geometrically shaped FRP composite parts will be addressed in this research, including developing enhanced simulation models to predict localized defects induced during rapid multi-layer forming and resin infiltration processes, predicting failure of FRP composite materials under high loading rates, and developing robust high-fidelity crash simulation models. These research outcomes will contribute to substantial weight reduction of EV structures and improved driving range, resulting in greater adoption and consequently a positive environmental impact from reduced sectorial greenhouse gas emissions. EV structures that are optimized to absorb maximum energy during a crash will greatly enhance occupant safety and improve battery protection from damage and fire hazards, thus, reducing crash fatalities. Finally, the Canadian-based automotive sector partners will adopt the research outcomes and gain an innovation-based competitive advantage by accelerating the rate of products to the global market.
Program
Alliance Grants
Recipient
Location
Ontario, Canada
Recipient Type
Academia
Type
Grant
Source
NSERC's Awards Data
As published
Application id
580246-2022
Name nom
Montesano, Giovanni G
Department département
Mechanical Engineering and Mechatronics
Organization id
33
Institution établissement
University of Waterloo
Province en
Ontario
Province fr
Ontario
Country en
CANADA
Country fr
CANADA
Fiscal year exercice financier
2023
Competition year année de concours
2022
Award amount
189952
Program id
ALLRP
Program name en
Alliance Grants
Program name fr
Subventions Alliance
Group en
RESEARCH PARTNERSHIPS
Group fr
PARTENARIATS DE RECHERCHE
Committee code
96
Committee name en
RPP Internal Decision Cttee
Committee name fr
Cté de décision interne - PPR
Area of application code
500
Area of application group en
Manufacturing processes and products
Area of application group fr
Procédés et produits industriels
Area of application en
Manufacturing processes and products
Area of application fr
Procédés et produits industriels
Research subject code
2108
Research subject group en
Mechanical engineering
Research subject group fr
Aerospace, aeronautical and automotive engineering
Research subject en
Génie mécanique
Research subject fr
Génie aérospatial, aéronautique et automobile
Application title
Development of safe ultra-lightweight liquid molded composite structures for next-generation electric vehicles
Keyword
Coupled process-crash models; Crashworthiness assessment; Electric vehicle lightweighting; Failure and damage mechanics; Finite element analysis; High-performance composite materials; Liquid composite molding processes; Multi-scale mechanics; Process simulation models; Strain rate-dependent materials
Application summary
The overarching goal of this research partnership is to support the integration of lightweight liquid molded fiber-reinforced plastic (FRP) composite materials into energy absorbing structures of next-generation electric vehicles (EVs). Current EVs are substantially heavier than gas-powered vehicles due to the immense mass of the battery cells and the fortified suspension and braking systems. A drastic reduction in weight through use of FRP composites will significantly improve the performance of vehicles and extend their driving range from a single charge, while simultaneously improving their crash safety. The proposed research will address a critical need to develop a novel integrated process-performance simulation platform to accurately predict the impact performance of as-manufactured lightweight high-pressure resin transfer molding (HP-RTM) FRP composite structures to support the design and fabrication of a new frontal crash component. Several key scientific challenges associated with rapid HP-RTM of geometrically shaped FRP composite parts will be addressed in this research, including developing enhanced simulation models to predict localized defects induced during rapid multi-layer forming and resin infiltration processes, predicting failure of FRP composite materials under high loading rates, and developing robust high-fidelity crash simulation models. These research outcomes will contribute to substantial weight reduction of EV structures and improved driving range, resulting in greater adoption and consequently a positive environmental impact from reduced sectorial greenhouse gas emissions. EV structures that are optimized to absorb maximum energy during a crash will greatly enhance occupant safety and improve battery protection from damage and fire hazards, thus, reducing crash fatalities. Finally, the Canadian-based automotive sector partners will adopt the research outcomes and gain an innovation-based competitive advantage by accelerating the rate of products to the global market.
