High energy impact testing using free fall mass is a crucial method for evaluating the structural integrity, and safety performance of automotive components subjected to sudden impact forces. This study focuses on assessing critical parts such as wheel rims, suspension knuckles, commonly exposed to unintentional impacts during vehicle operation, maintenance, or collisions. The test involves dropping a standardized mass from predetermined heights onto the component to simulate real-world impact scenarios. Key performance indicators include deformation, crack propagation, fracture resistance, and energy absorption capacity.
Wheel rims and knuckles are evaluated for their ability to maintain structural integrity under localized impact without compromising vehicle handling or safety. Seats and related interior structures are tested to ensure occupant protection during crash-like events. Other components, such as brackets, mounts, or housings, are included based on functional criticality and exposure risk.
Results from the free fall impact tests inform design optimizations, material selection (e.g., aluminium alloys, composites, high-strength steels), and manufacturing processes to improve product reliability and compliance with automotive safety requirements. This approach supports the development of robust vehicle systems capable of withstanding harsh real-world conditions, ultimately enhancing vehicle safety, performance, and customer satisfaction.