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Thermoplastic Roof Crush Countermeasure Design for Improved Roof Crush Resistant to Meet FMVSS-216
ISSN: 0148-7191, e-ISSN: 2688-3627
Published April 12, 2011 by SAE International in United States
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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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CitationKulkarni, 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.
- 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
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