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Thermoplastic Roof Crush Countermeasure Design for Improved Roof Crush Resistant to Meet FMVSS-216
Technical Paper
2011-01-1119
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
An automobile is designed to meet numerous impact events,
including frontal impact, side impact, rear impact, and roll over.
Roof crush resistance is a test defined by Federal Motor Vehicle
Safety Standard (FMVSS) 216. The intent of this test is to evaluate
the strength of the roof and supporting body structure during a
vehicle rollover. Steel countermeasures are typically used as
structural-reinforcing elements to the body structure to improve
the crush strength of a vehicle roof.
This paper presents a thermoplastic countermeasure (CM) design
as a light-weight solution to replace traditional steel
countermeasures. Two concepts are discussed in the paper: an
all-plastic countermeasure and a plastic/metal hybrid
countermeasure consisting of stamped steel with a thermoplastic
reinforcing rib structure. Finite Element (FE) methods using
LS-DYNA are used to evaluate the performance of these
countermeasure concepts. A generic Finite Element model of a sport
utility vehicle is used in the analysis. The countermeasure
concepts are assembled inside the B-Pillar and the crush strength
of the roof is evaluated as per FMVSS-216. This study shows that
the thermoplastic countermeasure can be developed with similar
stiffness and strength as steel countermeasure, yet with ~40-50%
mass savings. This paper provides an overview of the performance
for the thermoplastic countermeasures.
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Authors
Topic
Citation
Kulkarni, S. and Marks, M., "Thermoplastic Roof Crush Countermeasure Design for Improved Roof Crush Resistant to Meet FMVSS-216," SAE Technical Paper 2011-01-1119, 2011, https://doi.org/10.4271/2011-01-1119.Also In
References
- NHTSA http://www.nhtsa.dot.gov/cars/problems/Rollover/index.html
- Federal Motor vehicle Safety Standard No. 216 Roof Crush Resistance CFR 49 571.216 October 1997
- Federal Motor vehicle Safety Standard No. 216 Roof Crush Resistance CFR 49 571 and 585, Docket No. NHTSA-2009-0093
- Gatilao, F. Roesser, G. Reaume, B. “Overview of FMVSS 216a - Roof Crash Resistance Testing,” SAE Technical paper 2010-01-1020 2010 10.4271/2010-01-1020
- Mohan, Pradeep Nagabhushana, Vinay Kan, Cing-Dao Riley, Jon “Innovative Approach for Improving Roof Crush Resistance” LS-DYNA Anwenderforum Ulm 2006
- Hardikar, Narendra Somasekar, Bobba Makato, Suguwara Takaaki, Nemoto Ito, Shigeru “Design process for thermoplastic fenders - A case study of a multi-utility vehicle Body Panel development” AM&M 2010
- LS-DYNA User's Manual Livermore Software Technology Corporation