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CAE Driven Improvement in Frontal Offset Crash Performance of a Compact Car
Technical Paper
2014-01-0375
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
Offset crash compliance of a compact car is severe due to the compact layout and stringent fuel economy, weight and cost targets. Scope of the current work is to improve the structural crash performance of a compact car through CAE, in order to meet the offset frontal crash requirements as per ECE R94 Regulation.
The project has been classified in three main phases. First phase includes the evaluation of baseline vehicle in CAE. In order to ensure the accuracy of CAE prediction, a methodology for predicting Spotweld rupture was implemented. Using this methodology, it is possible to find out the location and time of spotweld rupture as well as propagation of spotweld rupture in CAE. CAE results of spotweld rupture prediction showed good agreement with the physical test. In second phase, design iterations were carried out in order to meet the performance targets of structural deformation. At critical locations of spotweld rupture, spotwelds were reinforced by addition of arc welds tugs and bolts. In third phase, all the structural countermeasures proposed in CAE were implemented in the prototype vehicle and physical crash test was conducted for final verification. Test and CAE results showed good correlation both in terms of the deformation and deceleration pulses. Significant improvement in offset crash performance of the vehicle was achieved with minimal weight and cost increase.
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Authors
Citation
Kumar, S., Bettakote, R., and Deb, P., "CAE Driven Improvement in Frontal Offset Crash Performance of a Compact Car," SAE Technical Paper 2014-01-0375, 2014, https://doi.org/10.4271/2014-01-0375.Data Sets - Support Documents
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References
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- Bois Paul Du , Chou Clifford C. , Fileta Bahig B. Khalil Tawfik B. , King Albert I. , Mahmood Hikmat F. Mertz Harold J. , Wismans Jac Vehicle Crashworthiness and Occupant Protection Book
- Kumagai Koushi , Shirooka Masakazu , Ohachi Jirou , Ogawa Toshirou et al. Rupture Modeling of Spotwelds Suitable for Crash FE Analysis in Vehicle Development Process 6th European LS-DYNA Users' Conference
- Livermore Software Technology Corporation LS-DYNA Version 971 Keyword User's Manual 2876 Waverley Way, Livermore, California, USA 2003
- Livermore Software Technology Corporation LS-DYNA Theoretical Manual 2876 Waverly Way, Livermore, California, USA 1998
- Failure mode of spot welds: interfacial versus pullout Science and Technology of Welding and Joining 2003 8 2