New Optimized Bus Structure to Improve the Roll-Over Test (ECE-R66) Using Structural Foam with High Strength Steel

Rollover resistant structures for coaches have been developed in the nineties, but recently, as the price of the steel has almost doubled only in the last year, the use of new materials for these superstructures has become more cost efficient. The price gap between high strength steel price and mild steel has been reduced and the use of this material is emerging into commercial vehicle industry. High strength steel may lead to weight and cost reduction but a new energy absorbing mechanism has been identified with the use of structural foam.

On this study a solution using high strength steels and structural foam has been designed to improve the energy absorption and reduce the final weight of a current rollover resistant bus structure. Several parts of the bus structure have been manufactured with the final selection of structural foam and high strength steel. The prototype parts have been used for test and manufacturability.