Optimisation of a vehicle energy absorbing steel component with experimental validation

The paper deals with the optimisation of a tapered tubular steel component to be used as an energy-absorbing device in the front structure of a vehicle body. Aim of the optimisation problem is the minimisation of a load uniformity parameter evaluated as the ratio between the maximum and the average crushing loads. The optimisation problem takes into account two design variables describing a tapered geometrical configuration, the diameter of the component at one of its bounds and the tapering length. Two improved geometrical configurations have been found and have been experimentally tested to verify the numerical results with impact velocities up to 10 m/s.     

铝合金材料在轿车车身轻量化中的应用研究

减轻汽车质量、降低燃油消耗和减少排放污染成为汽车工业发展的核心问题，车身的轻量化对于整车轻量化起着举足轻重的作用，采用轻质材料是车身减重的重要途径。该文以某轿车为对象，采用铝合金材料对车身11个主要覆盖件进行轻量化研究，该方案可以使车身减重53．1Kg，减重效果达到64．5％。采用显式有限元理论建立整车有限元模型，从满足整车耐撞安全性能的角度，在整车变形、整车与刚性墙的碰撞力、运动的速度和加速度、主要零部件的吸能等方面进行分析、评价，数值仿真验证了轻量化方案的可行性。     

On polynomial response surfaces and Kriging for use in structural optimization of crashworthiness

The accuracy of different approximating response surfaces is investigated. In the classical response surface methodology (CRSM) the true response function is usually replaced with a low-order polynomial. In Kriging the true response function is replaced with a low-order polynomial and an error correcting function. In this paper the error part of the approximating response surface is obtained from simple point Kriging theory. The combined polynomial and error correcting function will be addressed as a Kriging surface approximation.To be able to use Kriging the spatial correlation or covariance must be known. In this paper the error is assumed to have a normal distribution and the covariance to depend only on one parameter. The maximum-likelihood method is used to find the latter parameter. A weighted least-square procedure is used to determine the trend before simple point Kriging is used for the error function. In CRSM the surface approximation is determined through an ordinary least-square fit. In both cases the D-optimality criterion has been used to distribute the design points.From this investigation we have found that a low-ordered polynomial assumption should be made with the Kriging approach. We have also concluded that Kriging better than CRSM resolves abrupt changes in the response, e.g. due to buckling, contact or plastic deformation.     

Modeling and testing of energy absorbing lightweight materials and structures for automotive applications

As a consequence of the increasing demands in automotive industry concerning crashworthiness and passive safety, the concern for energy management and safety demands also increases. The goal of energy management is to reduce the forces and stresses on an occupant or a pedestrian during a crash event; in some cases it may be possible to reduce the forces by a factor of two. This requires usage of new advanced materials in automotive components. Energy absorbing foams and other lightweight materials like plastics and polymer composites are increasingly used in automotive industry. Hence, extensive study of energy absorbing behavior of these materials as well as the automotive components is needed for further improvements in numerical modeling and crash simulations. The paper enlightens recent advances in investigation of mechanical properties and energy absorption ability of the mentioned lightweight materials as well as modeling with finite element codes for crash simulations.     

The benefits of improved car secondary safety

The term 'secondary safety' refers to the protection that a vehicle provides its occupants when involved in an accident. This paper studies information from the British database of road accident reports between 1980 and 1998, to estimate the reduction in the number of occupant casualties over these years which may be attributed to improvements to secondary safety in cars.The paper shows that the proportion of driver casualties who are killed or seriously injured (KSI) is lower for modern cars than for older cars. The reduction of this proportion is used to assess the improvement in secondary safety. Statistical models are developed to represent the proportion with 'year of first registration' as one of the independent variables, although only an incomplete assessment of the benefits of improved secondary safety can be made with the available data. The assessment compares the number of casualties that would have been expected if secondary safety had remained at the level found in cars first registered in 1980 with the actual casualty numbers. It is estimated that improved secondary safety reduced the number of drivers KSI by at least 19.7% in 1998, in comparison with what might have occurred if all cars had had that lower level of secondary safety. This figure relates to all cars on the road in 1998, and rises to 33%, when confined to the most modern cars (those which were first registered in 1998).     

Do laboratory frontal crash test programs predict driver fatality risk? Evidence from within vehicle line variation in test ratings

A number of studies have examined whether the National Highway Traffic Safety Administration's (NHTSA) frontal crash test results reliably indicate the risk of fatality or injury in serious crashes. The conclusions of these studies are mixed. Generally, studies that examine crashes in the circumstances as close as possible to those of the laboratory test find that crash test results do predict real-world risk, but studies of crashes outside those specific circumstances find either no support for the predictive validity of crash test results or limited support with important inconsistencies. We provide a new test of the predictive validity of the crash test results using information from multiple crash tests within vehicle lines, thus controlling for systematic differences in driver behavior across vehicle lines. Among drivers of passenger cars, we find large, statistically significant differences in fatality risk for vehicles with one- to four-star NHTSA ratings versus a five-star rating. We also examine the Insurance Institute for Highway Safety's frontal offset crash test, though our sample of vehicle lines tested twice or more is considerably smaller than for NHTSA ratings. Our results also support the predictive validity of the frontal offset crash test results for passenger cars, but not for trucks.     

Crashworthiness design for functionally graded foam-filled bumper beam

Automotive bumper beam is an important component to protect passenger and vehicle from injury and damage induced by severe collapse. Recent studies showed that foam-filled structures have significant advantages in light weight and high energy absorption. In this paper, a novel bumper beam filled with functionally graded foam (FGF) is considered here to explore its crashworthiness. To validate the FGF bumper beam model, the experiments at both component and full vehicle levels are conducted. Parametric study shows that gradient exponential parameter m that controls the variation of foam density has significant effect on bumper beam’s crashworthiness; and the crashworthiness of FGF-filled bumper beam is found much better than that of uniform foam (UF) filled and hollow bumper beam. The multiobjective optimization of FGF-filled bumper beam is also performed by considering specific energy absorption (SEA) and peak impact force as the design objectives, and the wall thickness t, foam densities ρ_f1 and ρ_f2 (foam densities at the end and at mid cross section, respectively) and gradient exponential parameter m as design variables. The Kriging surrogate modeling technique and multiobjective particle swarm optimization (MOPSO) algorithm were implemented to optimize the FGF-filled bumper beam. The optimized FGF-filled bumper beam is of great advantages and it can avoid the harmful local bending behavior and absorb more energy than UF filled and hollow bumper beam. Finally, the optimized FGF-filled bumper beam is installed to a passenger car model, and the results demonstrate that the FGF-filled bumper beam ensures the crashworthiness performance of the passenger car while reduces weight about 14.4% compared with baseline bumper beam.     

Crashworthiness investigation of kagome honeycomb sandwich cylindrical column under axial crushing loads

For the classic thin-walled energy absorber, the energy dissipation during a collision is concentrated over relatively narrow zones. This means that a great deal of materials of the columns do not participate in the plastic deformation or not enter into the large plastic deformation stage. To expand the plastic deformation zones and improve the energy absorption efficiency, a new type of kagome honeycomb sandwich bitubal circular column is presented in this paper. This innovative impact energy absorber is made of two circular aluminum tubes filled with core shaped as a large-cell kagome lattice. The interaction effect, deformation mode and energy absorption characteristics of the composite structure are investigated numerically. Observing the collapsing process, it is found that the kagome lattices buckle first, which triggers the outer and inner skin tubes to fold locally. This behavior increases the plastic deformation areas. Moreover, the presence of the outer and inner tubes strengthens the buckling capacity of kagome cell. Furthermore, the folded tube walls intrude into the gap of the honeycomb cell, which further retards the collapse of the honeycomb cell. So the interaction effects between the honeycomb and column walls greatly improve the energy absorption efficiency. In addition, the effects of geometrical parameters of the kagome honeycomb on the structural crashworthiness are studied. It is found that the cell wall thickness and cell distribution (cell number in the circumferential direction) have distinct effects on the specific energy absorption. Besides, we also studied the foam-filled column with the same foam density as the kagome honeycomb and compared it with the kagome sandwich structure. It is found that the kagome sandwich column has higher mean crash force and better energy absorption characteristics.     

Energy absorbtion and mean crushing load of thin-walled grooved tubes under axial compression

In the present study, crashworthiness characteristics of thin-walled steel tubes containing annular grooves are studied. For this purpose, the grooves are introduced in the tube to force the plastic deformation to occur at predetermined intervals along the tube. The aims are controlling the buckling mode and predicting energy absorption capacity of the tubes. To do so, circumferential grooves are cut alternately inside and outside of the tubes at predetermined intervals. Quasi-static axial crushing tests are performed and the load-displacement curves are studied. Theoretical formulations are presented for predicting the energy absorption and mean crushing load. It is found a good agreement between the theoretical results and experimental findings. The results indicate that the load-displacement curve and energy absorbed by the axial crushing of tubes could be controlled by the introduction of grooves with different distances. Also, grooves can stabilize the deformation behavior and thus, the proposed method could be a good candidate as a controllable energy absorption element.     

Effect of plastic deformation and boundary conditions combined with elastic wave propagation on the collapse site of a crash box

Several papers have been published recently on the crashworthiness studies. The main task was to predict the energy absorption W_p and average collapse force in time of sheet steel structures. The main objective of this contribution is to design a component that allows absorbing and dissipating a high energy W_p allowing improvements of the survivability of passengers in vehicles. However, the range of applications is larger since it includes all civil and military applications related to safety of components, or more generally of construction elements being loaded by impacts or explosions. In the present 3D case, the aim of this numerical study on dynamic loading in adiabatic conditions of deformation is to analyze the effect of elastic wave propagation combined with plastic behavior on the collapse site of a rectangular tubular structure made of steel sheet. To demonstrate the strong coupling between the effects of strain-rate sensitivity, accounted for in the constitutive relation that is used in numerical simulations, with the process of elastic wave reflection on the boundary conditions, a series of numerical simulation was performed. It is shown in this numerical study that the strain-rate sensitivity influences the position of the first collapse site. Moreover, the first collapse initiation of a structure defines the level of power absorption. Since the process of folding may be combined with bending of the structure (in particular when a local buckling appears close to the opposite side of impact), in this non-axial case the energy absorption W_p decreases and the effectiveness of the structure to the energy absorption is insufficient.