| This dissertation presents a thorough analysis of Structural Reaction Injection Molded (S-RIM) composite material systems. The goal was to provide an optimum fiber reinforced architecture for the S-RIM manufacturing process, with the direct goal of improving performance of an automobile bumper beam. An optimized preform architecture was derived, based on through-the-thickness permeability and orthotropic mechanical properties. Micro- and mini-mechanics models were developed to determine theoretical orthotropic properties and stress distributions within the composite system. Coupled with the manufacturing process, material design was qualified through rigorous mechanical testing. Once determined, mechanical properties of the material were utilized in the design of the composite bumper beam. Due to geometrical non-linearity in response to loads, the finite element method was used to predict strain and stress throughout the continuum. Finally, a subroutine within the finite element code was developed to predict initiation and progression failure within a structure that is subjected to various mechanical loads. |
