Numerical Simulation of the Laser Scoring Line Behavior in Airbag Deployment

The airbag door system is one of the most delicate aspects in the design phase of a car instrument panel: seamless systems are increasingly used, which combine styling criteria with good functional performances. These systems typically include a tear seam, which may be obtained through laser scoring , to pre - determine the location of the opening during airbag deployment. The desig n of the scoring line is currently validated through experimental tests on real life exemplars, submitted to airbag deployment, resulting in high development times and relevant costs. This is the main reason which suggests proposing numerical simulation in the design phase, not to substitute actual part homologation by testing but in order to limit the scope and complexity of the experimental campaign, thus reducing the development costs and the time to market. So far, modeling the scoring line has been dif ficult due to limitations in the testing methods and simulation codes available to the industry. The methodology proposed in this paper takes advantage from the availability of a material law as LS - Dyna SAMP - 1, with polymer - dedicated plasticity, damage mod el and strain - rate dependent failure criteria, which is supported by local strain measurement used for material characterization. The method, here described in detail, is validated on a benchmark test, consisting in the real and virtual testing on a variet y of scoring profiles obtained on a polypropylene box submitted to high speed impact test.