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Roof Crush Variability Study Using Fea and Doe
Published October 31, 1995 by Automotive Technology Group, Inc. in United States
Federal Motor Vehicle Safety Standard (FMVSS) 216 requires the roof load-carrying capacity to be 1.5 times the unloaded vehicle weight (UVW) for trucks with a GVWR of 6000 pounds (2730 kg) or less and the smaller of 5000 lbs (2270 kg) or 1.5 times the UVW in the case of cars. FMVSS 216 also requires that this peak load be reached before the loading device surface travels 5 inches (127 mm). In the past, several of the roof crush tests performed on production vehicles and prototypes have shown considerable variation in test results. The objective of this paper is to evaluate the effects caused by the expected variation in material properties, gauges, and weld properties on the roof crush load. This was done by first developing a baseline finite element model of the vehicle and then performing a roof crush analysis using RADIOSS. The baseline model correlated well with the test data. A Design of Experiment (DOE) matrix was then used to quantify the contribution of each of the parameters identified in the DOE to the total variation in the peak load and energy. The results of this study indicate that the methodology of combining FEA and DOE can provide useful estimates of roof crush test variability.
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