Full-Scale Crash Testing Facilities for a Railway Vehicle

2012 ◽  
Author(s):  
Jin Sung Kim ◽  
Hyun Seung Jung ◽  
Tae Soo Kwon ◽  
Won Mok Choi ◽  
Seung Wan Son
Keyword(s):  
High Speed ◽  
Impact Test ◽  
Full Scale ◽  
Displacement Sensor ◽  
Crash Test ◽  
Railway Vehicle ◽  
Single Item ◽  
Railway Vehicles ◽  
Crash Testing ◽  
The Impact

KRRI (Korea Railroad Research Institute) has successfully performed several tens of impact tests of crash parts for a railway vehicles. Full-scale crash testing facilities were newly established including a crash barrier, dynamic load cell, high speed DAS (Data Acquisition System), a laser displacement sensor, dummies, a motor car and etc. This paper introduces series of impact test results using full-scale crash testing facilities. The impact test for railway vehicles consists of three categories, i.e. single item tests, module tests and crash structure tests. For single item tests, expansion tubes, composite tubes, collapsible tubes and etc. were tested. For module tests, a crash test of a light collision safety device with an expansion tube and triggering mechanism was performed. For crash structure tests, several full-scale crash tests were performed including front-end and cab structures with or without dummies. The crash testing equipment developed will be able to evaluate the occupant safety as well as the structural crashworthiness of a train.

scholarly journals Simulation of Energy Absorption Performance of the Couplers in Urban Railway Vehicles during a Heavy Collision

Machines ◽  
2021 ◽  
Vol 9 (5) ◽  
pp. 91
Author(s):  
Sunghyun Lim ◽  
Yong-hyeon Ji ◽  
Yeong-il Park
Keyword(s):  
Reaction Force ◽  
Crash Test ◽  
Railway Vehicle ◽  
Buffer System ◽  
Railway Vehicles ◽  
Hydraulic Shock Absorber ◽  
Coupling Buffer ◽  
Absorption Performance ◽  
Different Characteristics ◽  
The Impact

Railway vehicles are generally operated by connecting several vehicles in a row. Mechanisms connecting railway vehicles must also absorb front and rear shock loads that occur during a train’s operation. To minimize damage, rail car couplers are equipped with a buffer system that absorbs the impact of energy. It is difficult to perform a crash test and evaluate performance by applying a buffer to an actual railway vehicle. In this study, a simulation technique using a mathematical buffer model was introduced to overcome these difficulties. For this, a model of each element of the buffer was built based on the experimental data for each element of the coupling buffer system and a collision simulation program was developed. The buffering characteristics of a 10-car train colliding at 25 km/h were analyzed using a developed simulator. The results of the heavy collision simulation showed that the rubber buffer was directly connected to the hydraulic shock absorber in a solid contact state, and displacement of the hydraulic buffer hardly occurred despite the increase in reaction force due to the high impact speed. Since the impact force is concentrated on the vehicle to which the collision is applied, it may be appropriate to apply a deformation tube with different characteristics depending on the vehicle location.

Finite Element Simulation of a Strong-Post W-Beam Guardrail System

SIMULATION ◽  
2002 ◽  
Vol 78 (10) ◽  
pp. 587-599 ◽  
Author(s):  
Ali O. Atahan
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Full Scale ◽  
Nonlinear Finite Element ◽  
Crash Test ◽  
Original Design ◽  
Dynamic Interactions ◽  
Crash Testing ◽  
Element Simulation ◽  
Test Requirements

Computer simulation of vehicle collisions has improved significantly over the past decade. With advances in computer technology, nonlinear finite element codes, and material models, full-scale simulation of such complex dynamic interactions is becoming ever more possible. In this study, an explicit three-dimensional nonlinear finite element code, LS-DYNA, is used to demonstrate the capabilities of computer simulations to supplement full-scale crash testing. After a failed crash test on a strong-post guardrail system, LS-DYNA is used to simulate the system, determine the potential problems with the design, and develop an improved system that has the potential to satisfy current crash test requirements. After accurately simulating the response behavior of the full-scale crash test, a second simulation study is performed on the system with improved details. Simulation results indicate that the system performs much better compared to the original design.

A Sub-System Test Methodology for Simulating EEVC Side Impact

2000 ◽  
Author(s):  
Krishnakanth Aekbote ◽  
Srinivasan Sundararajan ◽  
Joseph A. Prater ◽  
Joe E. Abramczyk
Keyword(s):  
Full Scale ◽  
Test Method ◽  
Side Impact ◽  
Vehicle Body ◽  
Crash Test ◽  
Vehicle Performance ◽  
Test Methodology ◽  
Supporting Frame ◽  
The Impact ◽  
Crash Tests

Abstract A sled based test method for simulating full-scale EEVC (European) side impact crash test is described in this paper. Both the dummy (Eurosid-1) and vehicle structural responses were simulated, and validated with the full-scale crash tests. The effect of various structural configurations such as foam filled structures, material changes, rocker and b-pillar reinforcements, advanced door design concepts, on vehicle performance can be evaluated using this methodology at the early stages of design. In this approach, an actual EEVC honeycomb barrier and a vehicle body-in-white with doors were used. The under-hood components (engine, transmission, radiator, etc.), tires, and the front/rear suspensions were not included in the vehicle assembly, but they were replaced by lumped masses (by adding weight) in the front and rear of the vehicle, to maintain the overall vehicle weight. The vehicle was mounted on the sled by means of a supporting frame at the front/rear suspension attachments, and was allowed to translate in the impact direction only. At the start of the simulation, an instrumented Eurosid-1 dummy was seated inside the vehicle, while maintaining the same h-point location, chest angle, and door-to-dummy lateral distance, as in a full-scale crash test. The EEVC honeycomb barrier was mounted on another sled, and care was taken to ensure that weight, and the relative impact location to the vehicle, was maintained the same as in full-scale crash test. The Barrier impacted the stationary vehicle at an initial velocity of approx. 30 mph. The MDB and the vehicle were allowed to slide for about 20 inches from contact, before they were brought to rest. Accelerometers were mounted on the door inner sheet metal and b-pillar, rocker, seat cross-members, seats, and non-struck side rocker. The Barrier was instrumented with six load cells to monitor the impact force at different sections, and an accelerometer for deceleration measurement. The dummy, vehicle, and the Barrier responses showed good correlation when compared to full-scale crash tests. The test methodology was also used in assessing the performance/crashworthiness of various sub-system designs of the side structure (A-pillar, B-pillar, door, rocker, seat cross-members, etc.) of a passenger car. This paper concerns itself with the development and validation of the test methodology only, as the study of various side structure designs and evaluations are beyond the scope of this paper.

A Base Study to Investigate MASH Conservativeness of Occupant Risk Evaluation

2020 ◽  
Vol 6 (2) ◽  
Author(s):  
Nathan Schulz ◽  
Chiara Silvestri Dobrovolny ◽  
Stefan Hurlebaus ◽  
Harika Reddy Prodduturu ◽  
Dusty R. Arrington ◽  
...  
Keyword(s):  
Risk Evaluation ◽  
Injury Risk ◽  
Evaluation Criteria ◽  
Oblique Impact ◽  
Full Scale ◽  
Crash Test ◽  
Fe Model ◽  
Vehicle Interior ◽  
Space Model ◽  
The Impact

Abstract The manual for assessing safety hardware (MASH) defines crash tests to assess the impact performance of highway safety features in frontal and oblique impact events. Within MASH, the risk of injury to the occupant is assessed based on a “flail-space” model that estimates the average deceleration that an unrestrained occupant would experience when contacting the vehicle interior in a MASH crash test and uses the parameter as a surrogate for injury risk. MASH occupant risk criteria, however, are considered conservative in their nature, due to the fact that they are based on unrestrained occupant accelerations. Therefore, there is potential for increasing the maximum limits dictated in MASH for occupant risk evaluation. A frontal full-scale vehicle impact was performed with inclusion of an instrumented anthropomorphic test device (ATD). The scope of this study was to investigate the performance of the flail space model (FSM) in a full-scale crash test compared to the instrumented ATD recorded forces which can more accurately predict the occupant response during a collision event. Additionally, a finite element (FE) model was developed and calibrated against the full-scale crash test. The calibrated model can be used to perform parametric simulations with different testing conditions. Results obtained through this research will be considered for better correlation between vehicle accelerations and occupant injury. This becomes extremely important for designing and evaluating barrier systems that must fit within geometrical site constraints, which do not provide adequate length to redirect test vehicles according to MASH conservative evaluation criteria.

Design of the SAFER Emergency Gate Using LS-DYNA

2005 ◽  
Author(s):  
Robert W. Bielenberg ◽  
John D. Rohde ◽  
John D. Reid
Keyword(s):  
Impact Load ◽  
High Strength ◽  
Full Scale ◽  
Element Analysis ◽  
Worst Case ◽  
Crash Testing ◽  
Additional Protection ◽  
Energy Absorbing ◽  
The Impact ◽  
Gate Design

In recent years, NASCAR and the Indy Racing League have improved the safety of their racetracks through the installation of the Steel And Foam Energy Reduction barrier (SAFER). The new barrier consists of a high-strength, tubular steel skin that distributes the impact load to energy-absorbing foam cartridges in order to reduce the severity of the impact, extends the impact event, and provides the occupant of the race car additional protection. During installation of the SAFER barrier, the designers realized that certain race tracks were designed with the emergency track exit in the outside of the corner. Because the SAFER barrier needed to be installed in these corners, a gate mechanism had to be designed for the barrier that would provide access to the track while retaining the safety performance of the system. Full-scale crash testing of the first SAFER gate design showed that the gate did not posses sufficient capacity to handle the loads experienced during a worst-case impact scenario. Non-linear finite element analysis was then used to redesign the gate mechanism. The original gate design was simulated using LS-DYNA in order to validate the computational model. Modifications to increase the capacity of the gate mechanism were designed and analyzed until suitable results were obtained through simulation. Finally, the redesigned SAFER gate was successfully full-scale crash tested.

scholarly journals Finite Element Analysis of Impact Energy on Spur Gear

2018 ◽  
Vol 225 ◽  
pp. 06011 ◽  
Author(s):  
Ismail Ali Bin Abdul Aziz ◽  
Daing Mohamad Nafiz Bin Daing Idris ◽  
Mohd Hasnun Arif Bin Hassan ◽  
Mohamad Firdaus Bin Basrawi
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Impact Energy ◽  
High Speed ◽  
Impact Test ◽  
Impact Load ◽  
Gear Tooth ◽  
Test Equipment ◽  
Element Analysis ◽  
The Impact

In high-speed gear drive and power transmission, system impact failure mode always occurs due to the sudden impact and shock loading during the system in running. Therefore, study on the amount of impact energy that can be absorbed by a gear is vital. Impact test equipment has been designed and modelled for the purpose to study the impact energy on gear tooth. This paper mainly focused on Finite Element Analysis (FEA) of impact energy that occurred during simulation involving the impact test equipment modelling. The simulation was conducted using Abaqus software on critical parts of the test equipment to simulate the impact event and generate impact data for analysis. The load cell in the model was assumed to be free fall at a certain height which gives impact load to the test gear. Three different type of material for the test gear were set up in this simulation. Results from the simulation show that each material possesses different impact energy characteristic. Impact energy values increased along with the height of load drop. AISI 1040 were found to be the toughest material at 3.0m drop that could withstand up to 44.87N.m of impact energy. These data will be used to validate data in physical experiments in further study.

Analysis on Impact Loading at Rail Welds at High Speed

2008 ◽  
Author(s):  
Guangwen Xiao ◽  
Xinbiao Xiao ◽  
Zefeng Wen ◽  
Xuesong Jin
Keyword(s):  
Impact Loading ◽  
High Speed ◽  
Hertzian Contact ◽  
Railway Vehicle ◽  
Vehicle Speed ◽  
Explicit Integration ◽  
Normal Forces ◽  
Rail Irregularity ◽  
Multi Body ◽  
The Impact

When a railway vehicle passes through a track with different weld irregularities at high speed, the impact loading of the vehicle coupled with the track is investigated in detail using a coupled vehicle/track model. In this model, a half vehicle is considered and modeled as a multi-body system. In the track model, a Timoshenko beam resting on discrete sleepers is applied to model each rail. Each sleeper is modeled as a rigid body accounting for its vertical, lateral, roll motions. A moving sleeper support model is used to simulate the interaction of the vehicle and the track. The ballast bed is replaced with equivalent masses. The equivalent dampers and springs are used to replace the connections between the parts of the vehicle and track. In calculating the coupled vehicle and track dynamics, Hertzian contact theory and the creep force theory by Shen et al. are, respectively, used to calculate the normal forces and the creep forces between the wheels and the rails. The motion equations of the vehicle-track are solved by means of an explicit integration method. The weld rail irregularity is modeled by setting a local track vertical deviation at a rail weld joint, which is described with a simplified cosine function. In the numerical analysis the effect of the different wavelength, depth, the position of the welded joint in a sleeper span, and vehicle speed is taken into account. The numerical results obtained are greatly useful in the tolerance design of welded rail profile irregularity caused by damage and hand-grinding after rail welding.

THE EFFECTIVENESS OF THE COMPONENT IMPACT TEST METHOD FOR THE SIDE IMPACT INJURY ASSESSMENT OF THE DOOR TRIM

2008 ◽  
Vol 22 (09n11) ◽  
pp. 1766-1773
Author(s):  
YOUNGHAN YOUN ◽  
JEONG-SEO KOO
Keyword(s):  
Impact Test ◽  
Reaction Force ◽  
Design Guidelines ◽  
Test Method ◽  
Abdominal Injury ◽  
Side Impact ◽  
Crash Test ◽  
Conservation Of Energy ◽  
Absorption Energy ◽  
The Impact

The complete evaluation of the side vehicle structure and the occupant protection is only possible by means of the full scale side impact crash test. But, auto part manufacturers such as door trim makers can not conduct the test especially when the vehicle is under the developing process. The main objective of this study is to obtain the design guidelines by a simple component level impact test. The relationship between the target absorption energy and impactor speed were examined using the energy absorbed by the door trim. Since each different vehicle type required different energy levels on the door trim. A simple impact test method was developed to estimate abdominal injury by measuring reaction force of the impactor. The reaction force will be converted to a certain level of the energy by the proposed formula. The target of absorption energy for door trim only and the impact speed of simple impactor are derived theoretically based on the conservation of energy. With calculated speed of dummy and the effective mass of abdomen, the energy allocated in the abdomen area of door trim was calculated. The impactor speed can be calculated based on the equivalent energy of door trim absorbed during the full crash test. With the proposed design procedure for the door trim by a simple impact test method was demonstrated to evaluate the abdominal injury. This paper describes a study that was conducted to determine sensitivity of several design factors for reducing abdominal injury values using the matrix of orthogonal array method. In conclusion, with theoretical considerations and empirical test data, the main objective, standardization of door trim design using the simple impact test method was established.

Model Predictive Control Application to Flexible-Bodied Railway Vehicles for Vibration Suppression

2013 ◽  
Vol 10 ◽  
pp. 25-35
Author(s):  
P.E. Orukpe
Keyword(s):  
Model Predictive Control ◽  
Predictive Control ◽  
High Speed ◽  
Ride Comfort ◽  
The Body ◽  
Ride Quality ◽  
Linear Matrix ◽  
Railway Vehicle ◽  
Railway Vehicles ◽  
Effective Manner

In this paper, we apply model predictive control (MPC) based on mixed H2/H to active vibration control of the flexibility of railway vehicle to improve ride quality. However, the flexibility in the body of high-speed railway vehicles creates difficulties which in practice may result in the body structure being heavier than what it is supposed to be. The use of active suspension helps to model the vehicle and its flexibility in an effective manner. Conventional control approaches are compared with linear matrix inequality MPC technique using flexible-bodied railway vehicle as an example. The result indicates that the MPC technique performs better in improving ride comfort compared to the passive and classical techniques when flexible modes are present.

Impact Behaviour of Composite Materials by Using Low and High Speed Impact Tests

2012 ◽  
Vol 445 ◽  
pp. 189-194
Author(s):  
Enver Bulent Yalcin ◽  
Volkan Gunay ◽  
Muzeyyen Marsoglu
Keyword(s):  
Composite Materials ◽  
High Speed ◽  
Impact Test ◽  
Woven Fabrics ◽  
Impact Behaviour ◽  
High Speed Impact ◽  
Impact Tests ◽  
Data Acquisition Software ◽  
Damage Process ◽  
The Impact

The study presents the need for instrumented testing to optimizing materials against impact forces. The objective of the study is how the impact behaviour of composite materials is investigated by slow and high speed impact tests. Instron Dynatup 9250HV and Instron Dynatup 8150 Impact test machines (Fig.1.) are used which are located in TUBITAK-MRC, Materials Institute , Impact Test Laboratory". The damage process in composite materials under low and high velocity impact loading and the impact energy-displacement properties of the composite materials were investigated. Composite samples were produced by woven fabrics. The results are given as graphs and tables. The Impulse Data Acquisition software is used to send the data to computer.

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