Enhancing Energy Absorption in Rear Impact Events through Rail Extension Design and Material Variations

2025-36-0096

12/18/2025

Authors
Abstract
Content
Safety improvements in vehicle crashworthiness remain a primary concern for automotive manufacturers due to the increasing complexity of traffic and the rising number of vehicles on roads globally. Enhancing structural integrity and energy absorption capabilities during collisions is paramount for passenger protection. In this context, longitudinal rails play a critical role in vehicle crashworthiness, particularly in mitigating the effects of rear collisions. This study evaluates the structural performance of a rear longitudinal rail extender, characterized by a U-shaped, asymmetric cross-section, subjected to rear-impact scenarios. Seventy-two finite-element models were systematically developed from a baseline configuration, exploring variations in material yield conditions, sheet thickness, and targeted geometric modifications, including deformation initiators at three distinct positions or maintaining the original geometry. Each model was simulated according to ECE R32 regulation standards, ensuring validity and compliance with relevant safety criteria. Specific energy absorption (SEA), load uniformity, and structural acceleration were used as key measures of crashworthiness. Simulation outcomes indicated that reductions in thickness significantly increased SEA due to enhanced deformability. Thinner configurations demonstrated greater energy absorption and improved load uniformity, whereas thicker components increased structural rigidity, resulting in decreased energy absorption and higher accelerations transmitted to the vehicle’s B-pillar. Material properties had moderate influence, with higher-strength materials elevating accelerations. Geometric modifications, particularly deformation initiators at specific positions, substantially improved SEA, achieving enhancements up to 42% compared to baseline. These findings highlight the potential of strategic adjustments in geometry, material selection, and thickness to significantly enhance vehicle crashworthiness and occupant safety.
Meta TagsDetails
Pages
11
Citation
Souza Coelho Freitas, Victor de, Romulo Franco Pereira, and Daniel Souto de Souza, "Enhancing Energy Absorption in Rear Impact Events through Rail Extension Design and Material Variations," SAE Technical Paper 2025-36-0096, 2025-, https://doi.org/10.4271/2025-36-0096.
Additional Details
Publisher
Published
Dec 18, 2025
Product Code
2025-36-0096
Content Type
Technical Paper
Language
English