Thermoplastic Roof Crush Countermeasure Design for Improved Roof Crush Resistant to Meet FMVSS-216



SAE 2011 World Congress & Exhibition
Authors Abstract
An automobile is designed to meet numerous impact events, including frontal impact, side impact, rear impact, and roll over. Roof crush resistance is a test defined by Federal Motor Vehicle Safety Standard (FMVSS) 216. The intent of this test is to evaluate the strength of the roof and supporting body structure during a vehicle rollover. Steel countermeasures are typically used as structural-reinforcing elements to the body structure to improve the crush strength of a vehicle roof.
This paper presents a thermoplastic countermeasure (CM) design as a light-weight solution to replace traditional steel countermeasures. Two concepts are discussed in the paper: an all-plastic countermeasure and a plastic/metal hybrid countermeasure consisting of stamped steel with a thermoplastic reinforcing rib structure. Finite Element (FE) methods using LS-DYNA are used to evaluate the performance of these countermeasure concepts. A generic Finite Element model of a sport utility vehicle is used in the analysis. The countermeasure concepts are assembled inside the B-Pillar and the crush strength of the roof is evaluated as per FMVSS-216. This study shows that the thermoplastic countermeasure can be developed with similar stiffness and strength as steel countermeasure, yet with ~40-50% mass savings. This paper provides an overview of the performance for the thermoplastic countermeasures.
Meta TagsDetails
Kulkarni, S., and Marks, M., "Thermoplastic Roof Crush Countermeasure Design for Improved Roof Crush Resistant to Meet FMVSS-216," SAE Technical Paper 2011-01-1119, 2011,
Additional Details
Apr 12, 2011
Product Code
Content Type
Technical Paper