This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Design and Optimization of Crash-Box of Passenger Vehicle to Enhance Energy Absorption
ISSN: 0148-7191, e-ISSN: 2688-3627
Published March 25, 2019 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Frontal crash is the most common type of accidents in passenger vehicles which results in severe injuries or fatalities. During frontal crash, some frontal vehicle body has plastic deformation and absorbs impact energy. Hence vehicle crashworthiness is important consideration for safety aspect. The crash box is one of the most important parts in vehicle frontal structure assembly which absorb crash energy during impact. In case of frontal crash accident, crash box is expected to be collapsed by absorbing crash energy prior to the other parts so that the damage to the main cabin frame and occupant injury can be minimized. The main objective of this work is to design and optimize the crash box of passenger vehicle to enhance energy absorption. The modeling of the crash box is done in CATIA V5 and simulations are carried out by using ANSYS. The results show significant improvement in the energy absorption with new design of the crash box and it is validated experimentally on UTM. Further numerical analysis of bumper beam assembly is performed with consideration of new design of crash box. The meshing of bumper beam assembly is done in Hypermesh and frontal impact analysis is performed using LS-dyna as per standards. The result shows significant improvement of energy absorption in bumper beam assembly with optimized new design of crash box.
CitationSarage, S., Agrewale, M., and Vora, K., "Design and Optimization of Crash-Box of Passenger Vehicle to Enhance Energy Absorption," SAE Technical Paper 2019-01-1435, 2019, https://doi.org/10.4271/2019-01-1435.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
|[Unnamed Dataset 3]|
|[Unnamed Dataset 4]|
|[Unnamed Dataset 5]|
|[Unnamed Dataset 6]|
|[Unnamed Dataset 7]|
|[Unnamed Dataset 8]|
|[Unnamed Dataset 9]|
|[Unnamed Dataset 10]|
- National Crime Records Bureau, Ministry of Road Transport & Highway, Law Commission of India, Global Status Report on Road Safety.
- Ministry of Road Transport & Highways (MoRTH), Transport Research Wing, “Road Accidents in India - 2016,” New Delhi.
- Kalshetti, A.S. and Patil, S.V., “Energy Absorption of Varying Thickness Rectangular Section Crash Box for Quasi-Static Axial Loading,” International Engineering Research Journal Page387-391.
- Kahane, D.B. and Chandratre, K.V., “Experimental and Analytical Investigation for Impact Behavior of Different Shapes of Crash Box,” in International Conference on Ideas, Impact and Innovation in Mechanical Engineering (ICIIIME 2017), 5 6.
- Kim, H.C., Shin, D.K. et al., “Crashworthiness of Aluminum/CFRP Square Hollow Section Beam under Axial Impact Loading for Crash Box Application,” Composite Structures 112:1-10, 2014.
- Yu, H. and Chen, S., “Numerical Simulation of CFRP Thin-Walled Tubes Subjected to Quasi Static Axial Crushing,” SAE Technical Paper 2017-01-0465, 2017, doi:10.4271/2017-01-0465.
- Kumar, A.S., Himabindu, G. et al., “Experimental Investigations with Crush Box Simulations for Different Segment Cars Using LS-DYNA,” International Journal of Current Engineering and Technology E-ISSN 2277-4106, P-ISSN 2347-5161.
- Chandan, D.. Anand, C. Joshi, P. and Waghmare, S.A., “Crash Test for 40% Offset Frontal Bumper Car Analysis Using CAE,” Journal of Engineering Research and Studies E-ISSN0976-7916.
- Min, B.S. and Cho, J.U., “Impact Characteristic According to the Structure of Crash Box at the Vehicle,” Arch. Metall. Mater. 62 2B:1047-1050, 2017.
- Maddever, W. and Guinehut, S., “Use of Aluminum Foam to Increase Crash Box Efficiency,” SAE Technical Paper 2015-01-0704, 2015, doi:10.4271/2015-01-0704.
- Schwanitz, P., Werner, S., Zerbe, J., and Gohlich, D., “Robust Optimization of Vehicle Crashboxes,” SAE Technical Paper 2014-01-0397, 2014, doi:10.4271/2014-01-0397.
- Insurance Institute for Highway Safety (IIHS) Low-Speed Crash Test Protocol, Version II, August 1997.
- Research Council for Automobile Repair (RCAR) front Crash Test Standard, Issue 2.2, July 2011.
- Euro Ncap Full Width Frontal Impact Testing Protocol, Version 1.0.4, Nov. 2017.
- Simhachalam, B., Krishnasrinivas, and Lakshmanarao, C., “Compression Behavior and Energy Absorption of Aluminum Alloys and Steel for Automotive Application,” SAE Technical Paper 2013-26-0080, 2013, doi:10.4271/2013-26-0080.
- Ando, K., Nakagawa, K., Araki, T. et al., “Impact simulation of the CFRP Structure for a GT-Car,” SAE Technical Paper 2003-01-2768, 2003, doi:10.4271/2003-01-2768.
- Steel Bumper Systems for Passenger Vehicles and Light Trucks Fifth Edition (Steel Market Development Institute, May 2013).
- Bade, S. and C, L., “Compression and Energy Absorption of Aluminum Alloy AA6061 and AA7005 Tubes Using Experimental and Simulation Methods,” SAE Technical Paper 2015-26-0169, 2015, doi:10.4271/2015-26-0169.
- Jang, H., Lee, H., Yi, S. et al., “Cross-Section Design of the Crash Box to Maximize Energy Absorption,” SAE Technical Paper 2011-28-0110, 2011, doi:10.4271/2011-28-0110.
- Tekavde, N., Srinivas, S., Banthia, V., and Mittemari, S., “Redesign of Crash Box for Enhanced Energy Absorption in Low Velocity Impact,” SAE Technical Paper 2016-28-0254, 2016, doi:10.4271/2016-28-0254.
- Wei, Z., Karimi, H., and Robbersmyr, K., “Analysis of the Relationship between Energy Absorbing Components and Vehicle Crash Response,” SAE Technical Paper 2016-01-1541, 2016, doi:10.4271/2016-01-1541.