Modelling of an Anti-Intrusion Plate in CFRP for a Formula Student Vehicle

This thesis focuses on the development of structural solutions for the safety critical system called Impact Assembly of Formula SAE vehicles, with particular attention to the Anti-Intrusion Plate. After experimental characterization of the composite materials (tensile and in-plane shear tests), the mechanical behavior was modeled using LS-DYNA. The first part reproduces the failure observed in a sandwich Anti-Intrusion Plate with honeycomb core, tested in combination with an origami-shaped CFRP Impact Attenuator. Through experimental tests and FEM simulations, it was shown that the sandwich architecture is unsuitable for concentrated loads, leading to premature collapse. To overcome these limitations, the research focused on a new monolithic (full CFRP) configuration. Using drop-weight impact tests and numerical modeling, the above configuration was studied and found capable of meeting Formula SAE requirements and ensuring weight reduction. This work demonstrates how an integrated experimental–numerical approach enables the design of an innovative, lightweight, and high-performance Anti-Intrusion Plate, paving the way for further optimizations in layup configurations and coupling with the Impact Attenuator.