This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Analytical Crush Resistance of Hybrid Aluminum-RCM Roof Structures
Technical Paper
2000-01-0066
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Event:
SAE 2000 World Congress
Language:
English
Abstract
The crush resistance of roof structures is critical to minimizing injuries and enhancing occupant survival during rollover crashes. Federal Motor Vehicle Safety Standard FMVSS 216 requires the roof structure to resist a load equal to one and one half (1&1/2) the unloaded weight of the vehicle during the first 127 millimeters (five inches) of deformation.
This paper discusses the analytical methodologies applied and challenges encountered developing a hybrid Aluminum-Random Chop Material (RCM) roof structure. The roof structure materials are extruded 6260T6 aluminum and RCM. This hybrid roof structure has to satisfy not only the FMVSS 216 roof crush resistance, but also packaging, torsional stiffness and head impact requirements. Due to packaging constraints, the structure has to be developed without the roof bow at the B-pillar level. Head impact and manufacturing requirements, for current architecture and materials, necessitated limiting the inner thickness of the extruded 6260T6 Aluminum pillars, headers and roof side rails to 1.8 mm.
A composite component code COMCOLLAPSE was used in parallel with a stability and strength crush code SECOLLAPSE in the development, design and analysis of the Aluminum-RCM roof structure components. An in-house non-linear beam finite element code VCRUSH was used in the design and analysis of the roof structural system. The newly developed hybrid Aluminum-RCM roof structure exceeded all FMVSS 216 design and certification requirements.
Recommended Content
| Ground Vehicle Standard | Inverted Vehicle Drop Test Procedure |
| Technical Paper | The Raisable Roll-Over Bar of the New Mercedes-Benz Roadster |
| Technical Paper | Application of Extreme Value Theory to Crash Data Analysis |
Authors
Citation
Baccouche, M., Wagner, D., and Ghannam, M., "Analytical Crush Resistance of Hybrid Aluminum-RCM Roof Structures," SAE Technical Paper 2000-01-0066, 2000, https://doi.org/10.4271/2000-01-0066.Also In
References
- Baccouche M. R. Mahmood H. F. Shivakumar A.K. Jawad S.A. “Crashworthiness Performance of Space Frame Aluminum Structure in NCAP's 35 mph Full Frontal,” The 1999 ASME Crashworthiness, Occupant Protection and Biomechanics in Transportation Systems Nashville, TN November 14-19 1999
- Jawad S. A. Mahmood H.F. Baccouche M.R. “Smart Structure for Improving Crashworthiness in Vehicle Frontal Collisions,” The 1999 ASME Crashworthiness, Occupant Protection and Biomechanics in Transportation Systems Nashville, TN November 14-19 1999
- Baccouche M. R. Mahmood H. F. “Design of Extruded Aluminum Space Frame Front End Structures for Crash Energy Management - Part II,” The 1998 ASME Crashworthiness, Occupant Protection and Biomechanics in Transportation Systems Anaheim, CA November 15-20 1998
- Weinhold V. Baccouche M. R. Hasan A. “Crashworthiness of Aluminum Components,” The 1998 ASME Crashworthiness, Occupant Protection and Biomechanics in Transportation Systems Anaheim, CA November 15-20 1998
- Mahmood H. F. Baccouche M. R. “Design of Extruded Aluminum Space Frame Front End Structures for Crash Energy Management - Part I,” The 1997 ASME Crashworthiness, Occupant Protection and Biomechanics in Transportation Systems Dallas, TX Nov. 16-21 1997 225 17 36
- Mahmood H. F. Baccouche M. R. “Design of Automotive Body Structure for Roof Crush,” The 1996 ASME Crashworthiness, Occupant Protection and Biomechanics in Transportation Systems Atlanta, GA November 17-22 1996
- Mahmood H. F. Baccouche M. R. “Designing for Offset Crush: A Trade-Off in Constraints,” The 1995 Proceedings of the Ninth International Conference on Vehicle Structural Mechanics and CAE Troy, MI April 4-6 1995
- McGregor, I.J. Seeds, A.D. Nardini, D. “The Design of Impact Absorbing Members for Aluminum Structured Vehicles,” SAE Technical Paper Series 900796 1990
- Herbst, B. Forrest, S. Meyer, S.E. “Strength Improvements to Automotive Roof Components,” SAE Technical Paper Series 980209 1998
- D'Aprile, F. Icardi, U. “Evaluation of Vehicle Composite Structures,” SAE Technical Paper Series 905176 1990
- Ramoo, R. Guenther, D.A. “On The Optimum Design of Composite Roof Structures,” SAE Technical Paper Series 890548 1989
- Friedman, D. Herbst, B. “The Relationship Between Vertical Velocity and Roof Crush in Rollover Crashes,” SAE Technical Paper Series 980211 1998