A review of multiscale FE modelling of lightweight composite for automotive part

In automotive design, composite materials are increasingly being considered as alternatives to metals due to their superior strength-to-weight ratios and corrosion resistance. However, their high costs and complex behaviour, arising from their heterogeneous nature, present challenges in studying these materials. The finite element method (FEM) has become a crucial tool for analysing composites under various conditions. This review focuses on the finite element modelling (FEM) of composite materials, emphasizing the material models and damage criteria used in simulation software, material properties, failure criteria and element types utilized in automotive components. From a modelling perspective, the review covers micro, meso and macro levels of FEM, explaining how these scales contribute to accurate simulations. Regarding material properties, the discussion includes various constitutive relationships, theories and mechanical characteristics relevant to modelling composites. The types of finite elements, such as solid, shell and cohesive elements, are explored, highlighting their roles in capturing the behaviour of composites during simulations. The article also delves into failure criteria, outlining the methods developed and implemented for predicting the failure of composite materials in simulations. Additionally, the review covers specific automotive components like fenders, leaf springs, Drive Shaft and crash boxes, illustrating how FEM has been used to optimize their designs and the benefits of using composite materials in these applications.