scholarly journals Numerical simulation of crashworthiness parameters for design optimization of an automotive crash-box

2022 ◽  
Vol 13 ◽  
pp. 3
Author(s):  
Prabhaharan S. A. ◽  
G. Balaji ◽  
Krishnamoorthy Annamalai
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Energy Absorption ◽  
Absorption Capacity ◽  
Operating Conditions ◽  
Crash Test ◽  
Testing Time ◽  
Frontal Impacts ◽  
Design Variables ◽  
Esi Group

Automotive manufacturers rely on rigorous testing and simulations to construct their vehicles durable and safe in all aspects. One such vital factor is crash safety, otherwise known as crashworthiness. Crash tests are conventional forms of non-destructive methods to validate the vehicle for its crashworthiness and compatibility based on different operating conditions. The frontal impact test is the most primary form of crash test, which focuses on improving passenger's safety and comfort. According to NHTSA, a vehicle is rated based on these safety criteria, for which automobile manufacturers conduct a plethora of crash-related studies. Numerical simulation aids them in cutting down testing time and overall cost endured by providing a reliable amount of insights into the process. The current study is aimed at improving the crashworthiness of a crash box in a lightweight passenger car, such that it becomes more energy absorbent in terms of frontal impacts. All necessary parameters such as energy absorption, mean crush force, specific energy absorption, crush force efficiencies are evaluated based on analytical and finite element methods. There was a decent agreement between the analytical and simulation results, with an accuracy of 97%. The crashworthiness of the crash box was improved with the help of DOE-based response surface methodology (RSM). The RSM approach helped in improving the design of the crash box with enhanced EA & CFE by 30% and 8.8% respectively. The investigation of design variables on the energy absorption capacity of the thin-walled structure was also done. For the axial impact simulations, finite element solver Virtual Performance Solution − Pam Crash from the ESI group is used.

Energy-Based Crashworthiness Optimization for Multiple Vehicle Impacts

2004 ◽  
Author(s):  
H. Fang ◽  
K. Solanki ◽  
M. F. Horstemeyer
Keyword(s):  
Finite Element ◽  
Energy Absorption ◽  
Absorption Capacity ◽  
Full Scale ◽  
Side Impact ◽  
Frontal Impact ◽  
Vehicle Model ◽  
Energy Absorption Capacity ◽  
Side Impacts ◽  
Design Variables

In this paper, we use a full-scale finite element vehicle model of a 1996 Dodge Neon in simulating two types of vehicle crashes, offset-frontal and side impacts. Based on an analysis of the vehicle’s histories of internal energy absorption under both impacts, we select twenty components as design variables in the optimization of the vehicle’s weight without decreasing the vehicle’s energy absorption capacity and energy absorption rate. We use the second-order polynomials in creating the metamodels for the response functions of energy absorption under both impacts. The optimization result shows a significant reduction on the total weight of the selected components. The LS-DYNA MPP v970 and a full-scale finite element vehicle model of 320,872 nodes and 577,524 elements are used in the simulations. A simulation of 100 ms offset-frontal impact takes approximately 17 hours with 36 processors on the IBM Linux SuperCluster, which has a total of 1038 Intel Pentium III 1.266 GHz processors and 607.5 GB RAM. A simulation of 100 ms side impact takes approximately 29 hours with the same condition as the offset-frontal simulation.

Experimental and numerical study on the crashworthiness evaluation of an intercity coach under frontal impact conditions

2020 ◽  
Vol 234 (13) ◽  
pp. 3026-3041 ◽  
Author(s):  
Mehmet Ali Güler ◽  
Muhammed Emin Cerit ◽  
Sinem Kocaoglan Mert ◽  
Erdem Acar
Keyword(s):  
Finite Element ◽  
Energy Absorption ◽  
Numerical Study ◽  
Absorption Capacity ◽  
The Body ◽  
Steering Wheel ◽  
Energy Absorption Capacity ◽  
Bus Structure ◽  
Bus Body ◽  
Absorption Characteristics

In this study, the energy absorption capacity of a front body of a bus during a frontal crash was investigated. The strength of the bus structure was examined by considering the ECE-R29 European regulation requirements. The nonlinear explicit finite element code LS-DYNA was used for the crash analyses. First, the baseline bus structures without any improvements were analyzed and the weak parts of the front end structure of the bus body were examined. Experimental tests are conducted to validate the finite element model. In the second stage, the bus structure was redesigned in order to strengthen the frontal body. Finally, the redesigned bus structure was compared with the baseline model to meet the requirements for ECE-R29. In addition to the redesign performed on the body, energy absorption capacity was increased by additional energy absorbers employed in the front of bus structure. This study experimentally and numerically investigated the energy absorption characteristics of a steering wheel armature in contact with a deformable mannequin during a crash. Variations in the location of impact on the armature, armature orientation, and mannequin were investigated to determine the effects of the energy absorption characteristics of the two contacting entities.

scholarly journals Methodology for scaling finite element dummy and validation of a Hybrid III dummy model in crashworthiness simulation

2019 ◽  
Vol 2 (SI2) ◽  
pp. SI105-SI113
Author(s):  
Lý Hùng Anh ◽  
Dinh Bao Nguyen ◽  
Anh Huy Nguyen
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Head Injury ◽  
Automobile Industry ◽  
Real Life ◽  
Crash Test ◽  
Brain Concussion ◽  
Head Injury Criterion ◽  
Hybrid Iii ◽  
Pedestrian Crashes

For study of car-pedestrian crashes, it is two common methods that can be employed: conducting crash tests with mechanical dummies and simulating car crashes on computer. The former is a traditional way and gives good results compared with real life car impact; however, its disadvantage is very expensive test equipment and generally more time-consuming than the latter because after every crash test, experimental vehicles as well as dummies need repairing to be ready for the next experiments. Therefore, crash test simulation using finite-element method is more and more popular in the automobile industry because of its feasibility and cost saving. The majority of finite element dummy models used in crash simulation. Particularly, it is popular to use Hybrid III 50th dummy model which is built based on fiftieth percentile male (equal in height and weight of the average North American). Thus, it is necessary to develop a scaling algorithm to scale a reference dummy size into a desired one without rebuilding the entire model. In this paper, the Hybrid III dummy model provided by LS-DYNA software is scaled to suit Vietnamese biomechanical characteristics. Scaling algorithm comprises dummy geometry, inertial properties and joint properties is utilized. In order to estimate level of head injury – brain concussion by using numerical simulation, the correlation between Head Injury Criterion (HIC) and Abbreviated Injury Scale (AIS) is introduced. In addition, the Hybrid III dummy model in crashworthiness simulation is presented in key frame picture. Numerical simulation approach is validated by comparing results of head acceleration and HIC obtain from this study with experimental data and numerical simulation results in other publication

Optimization Design of Extrusion Die Channels for Polymer Profile

2010 ◽  
Vol 148-149 ◽  
pp. 1726-1729
Author(s):  
Qi Bing Wang ◽  
Zhi Ming Wang ◽  
An Hua Peng
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Objective Function ◽  
Optimization Design ◽  
Database System ◽  
Flow Speed ◽  
Flow Uniformity ◽  
Extrusion Die ◽  
Design Variables ◽  
Finite Element Numerical Simulation

The objective function is the same flow speed of each sub-filed of product section at exit of the extrusion die for the complexity of hollow polymer profile, and design variables are impact on the flow uniformity of the space above the compression, the example based on finite element numerical simulation and based on the CAD/CAE/ERP database system, the result showed the velocity is obviously improved after the optimization, well positioned to meet the requirements of customer.

scholarly journals Numerical simulation applied to milk cooling

2021 ◽  
Vol 29 ◽  
pp. 122-128
Author(s):  
Renan Rezende ◽  
Ednilton Tavares de Andrade ◽  
Jefferson Luiz Gomes Correa ◽  
Ricardo Rodrigues Magalhães
Keyword(s):  
Experimental Data ◽  
Numerical Simulation ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Computational Model ◽  
Operating Conditions ◽  
Real System ◽  
Cooling Process ◽  
Element Analysis ◽  
The Real

A model is a representation of a real system that can be analysed and yield predictions under different operating conditions. The aim of this study was to model a milk cooling tank that cools milk to 4 °C to preserve its quality after milking at the farm. The model was developed and simulated using the software Ansys for finite element analysis. The results from the simulations were compared to experimental data. The model simulated milk cooling in the tank with an error lower than 2%, which is considered acceptable for numerical simulations. In other words, the model satisfactorily represents the real system. Thus, alternatives can be directly tested in the computational model to improve and optimise the milk cooling process and to better use the system without actually implementing them in the real system.

Numerical Simulation of Blast Mitigation Cladding with Gradient Metallic Foam Core

2011 ◽  
Vol 82 ◽  
pp. 461-466 ◽  
Author(s):  
Jing De Li ◽  
Hong Yuan Zhou ◽  
Guo Wei Ma
Keyword(s):  
Numerical Simulation ◽  
Density Gradient ◽  
Energy Absorption ◽  
Absorption Capacity ◽  
Metallic Foam ◽  
Foam Core ◽  
Blast Mitigation ◽  
Energy Absorption Capacity ◽  
Blast Energy ◽  
Gradient Density

In the present study, numerical simulation is performed by using the commercial software ANSYS/LS-DYNA to investigate the various effects on crushing stress and energy absorption capacity of the blast mitigation cladding with gradient density aluminium foam in irregular manners, a 2D Voronoi technique is employed to generate the stochastic gradient metallic foam core. Results show that a properly designed energy absorption foam cladding with graded density is able to absorb high blast energy while with a lower force transferred to the substrate or the protected structure. Parametric study with respect to impact velocity and density gradient indicates that the density gradient foam cladding is effective in increasing energy absorption capacity especially under high velocity blast load.

Energy Absorption Capacity of Expanding Tube with Fiber-Reinforcement

2014 ◽  
Vol 626 ◽  
pp. 57-61
Author(s):  
Gin Boay Chai ◽  
Guo Xing Lu
Keyword(s):  
Finite Element ◽  
Energy Absorption ◽  
Reaction Force ◽  
Three Dimensional ◽  
Absorption Capacity ◽  
Finite Element Analyses ◽  
Absorption Mechanism ◽  
Energy Absorption Capacity ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

Abstract. This contribution presents the investigation of energy absorption mechanism of metal tubes and composite-wrapped metal tubes subjected to a diametric deformation via an expansion process. In the experiments, the expansion of the tubes was performed under quasi-static loading using a conical-cylindrical expansion die. The experimental results are repeatable and thus reliable. An extensive finite element analyses and experimental investigation were carried out in parallel. Both two-dimensional and three-dimensional finite element models were created based on the actual experimental geometrical and material parameters. Results from the finite element analyses correlate rather well with the experimental data. Glass fibre-wrapped metal tubes showed an increased steady-state reaction force which in turn reflects better specific energy absorption capacity for every layer of composite wrapped as compared to bare metal tubes.

Crashworthiness optimization of hierarchical hexagonal honeycombs under out-of-plane impact

2020 ◽  
pp. 095440622093910
Author(s):  
M Altin ◽  
E Acar ◽  
MA Güler
Keyword(s):  
Finite Element ◽  
Energy Absorption ◽  
Specific Energy ◽  
Numerical Study ◽  
Absorption Capacity ◽  
Optimization Approach ◽  
Energy Absorption Capacity ◽  
Specific Energy Absorption ◽  
Honeycomb Structures ◽  
Out Of Plane

This paper presents a numerical study of regular and hierarchical honeycomb structures subjected to out-of-plane impact loading. The specific energy absorption capacity of honeycomb structures via nonlinear explicit finite element analysis is investigated. The constructed finite element models are validated using experimental data available in the literature. The honeycomb structures are optimized by using a surrogate-based optimization approach to achieve maximum specific energy absorption capacity. Three surrogate models polynomial response surface approximations, radial basis functions, and Kriging models are used; Kriging models are found to be the most accurate. The optimum specific energy absorption value obtained for hierarchical honeycomb structures is found to be 148% greater than that of regular honeycomb structures.

Theoretical prediction and crashworthiness optimization of multi-cell polygonal tubes

2017 ◽  
Vol 22 (2) ◽  
pp. 190-219 ◽  
Author(s):  
Hanfeng Yin ◽  
Guilin Wen ◽  
Zhonghao Bai ◽  
Zhewu Chen ◽  
Qixiang Qing
Keyword(s):  
Numerical Simulation ◽  
Theoretical Prediction ◽  
Energy Absorption ◽  
Optimization Method ◽  
Absorption Capacity ◽  
Numerical Results ◽  
Multi Objective Optimization ◽  
Vehicle Engineering ◽  
Energy Absorption Capacity ◽  
Multi Objective

Multi-cell polygonal tubes are highly efficient energy absorbers and widely used in vehicle engineering. There is no doubt that the structure designers have strong interest to know which kind of multi-cell polygonal tube has the best crashworthiness. However, the comparative study on the crashworthiness of multi-cell polygonal tubes with different edges was quite few. In this paper, the multi-cell polygonal single and bitubular tubes were investigated using the numerical simulation and theoretical prediction methods. Theoretical expressions of the mean crushing forces of the multi-cell polygonal single and bitubular tubes with arbitrary edge were derived by employing the simplified super folding element theory. The theoretical predictions well coincided with the numerical results. Based on the theoretical and numerical results, it can be found that the multi-cell polygonal bitubular tube with 18 edges had the best energy absorption capacity. In order to further improve the crashworthiness of multi-cell polygonal tube, a metamodel-based multi-objective optimization method which jointly employed the finite element simulation, metamodelling method and non-dominated sorting genetic algorithm ver. II multi-objective optimization algorithm was developed. Based on this metamodel-based optimization method, the multi-cell polygonal bitubular tube with 18 edges was optimized. The theoretical prediction also had good agreement with the numerical simulation result for the optimal design. The optimal multi-cell polygonal tube not only had excellent energy absorption capacity but also had stable collapse mode.

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