Simulation of Outer Door Handle and Latch Responses in Side Impact using Component Test Methodology

A dynamic component test methodology using a door sub-system was developed to simulate the outside door handle/latch responses (accelerations and deformations) as in a full-vehicle NHTSA FMVSS 214 side impact test. The test methodology consists of a door sub-system (with door inner components) which is allowed to pivot by means of a hinge at the top of the door. The lateral structural load path affecting the door/rocker response was accounted and simulated (obtained from full-vehicle FE analysis) in this methodology by means of an energy absorbing material (Aluminum honeycomb) of predetermined stiffness. A bullet sled simulating the Moving Deformable Barrier (MDB) surface and stiffness at the same relative location to the door/rocker (as in full-vehicle test) strikes the stationary hinged door at an initial velocity of approx. 30 mph (longitudinal component of crab cart velocity of 33.5 mph). Upon impact, the door sub-system rotates about the hinge simulating both the acceleration at the outer handle and latch, and overall deformation of the door. The front door responses (acceleration and velocity) near outer handle and latch from the component test methodology are compared to full-vehicle for validation.