Finite Element Modelling and Analysis of Composites Toecaps

Composite toe-caps have attracted considerable attention due to their advantageous properties over traditional metallic toe-caps. However, the anisotropic properties of composite materials also make the toe-cap performance more complex to analyse. This project aims at developing a Finite Element (FE) model for composite toe-caps with the aid of compression testing data. The geometry of the toe-cap was first scanned and imported into an FEA software package to create a workable FE model. The method was then validated by comparing the FE model with experimental results of steel toe-caps. Manufacturing, modelling and testing of custom-made composite toe-cap samples were then carried out. Modelling outputs of composite toe-caps were compared with compression test data for validation. The stress distributions and deformations of the toe-caps were also analysed. Modelling of the steel and composite toe-caps was realized using LS-DYNA Solver and Pre Post. All FE analyses were modelled with reference to European Standards. The developed FE models can in the future be used to model toe-caps with various materials to determine the effects of fibre orientation relating to structural strength, and to achieve structural optimisation.