Optimization of Console Armrest Design for Reduction of G-values in Head Impact Testing

Head injuries from interior impacts during vehicle accidents are a significant cause of fatalities in India. Data from the National Crime Records Bureau (NCRB) for 2023 reveals that approximately 15% of the total 150,000 road fatalities were due to head impacts on vehicle interiors, resulting in about 22,500 deaths. Thus, head impact protection in a car crash is a key during the design of vehicle interiors. IS 15223 and ECE R21 provides specific guidelines for head impact testing of instrument panels and consoles in vehicles to ensure compliance with safety standards and minimize the risk of head injuries during collisions. By systematically addressing each aspect of IS 15223 and ECE- R21 in the design, testing, and documentation phases, manufacturers can ensure that console armrests are optimized for safety. This approach not only helps meet regulatory standards but also enhances overall occupant protection in vehicles during collisions. The objective of this paper is to design a console armrest that meets stringent head impact testing requirements thereby enhancing occupant safety in automotive applications. The research focuses on optimizing the armrest’s structural integrity and material composition to absorb and dissipate impact energy effectively. The paper explores the design and optimization of a console armrest features aimed at reducing the G-forces experienced during head impact tests, ensuring compliance with stiffness targets. A combination of detailed simulation and extensive physical testing validates the design effectiveness in mitigating head injuries by lowering acceleration values. The results demonstrate that the refined armrest design not only meets the regulatory stiffness criteria but also significantly improves passenger safety in collision scenario.