Browse Topic: Crashworthiness

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Multi-material topology optimization using difference-based equivalent static load method2026-01-0173To be published on 04/07/2026
Topology optimization (TO) has become a powerful tool for generating lightweight structural designs. TO has been widely applied to linear static problems, where analytical sensitivities are easy to obtain. However, crashworthiness design requires nonlinear dynamic analysis, for which analytical sensitivities are generally not available. To extend TO into crash problems, approximation methods such as the Equivalent Static Load (ESL) method have been developed. ESL replaces the nonlinear problem with a series of linear static subproblems, ensuring that the displacement fields match at certain time steps. These subproblems can then be efficiently solved using standard TO techniques. A key limitation of ESL is that it relies on the initial mesh for all subproblems, which reduces accuracy for highly nonlinear crash responses. To address this, Triller proposed the difference-based ESL (DiESL) method, which updates the mesh in each subproblem to the deformed configuration, therefore improving
Huang, Yuhao, Kim, Il Yong
Designing an e-SUV to Meet Global Front Crash Safety Standards2026-01-0580To be published on 04/07/2026
Vehicle crashworthiness has improved tremendously over the past 20 years with increasing scenarios being defined and assessed by governments and nonprofits every few years. Bodies such as NTHSA, IIHS and EuroNCAP created safety ratings to distinguish objectively which vehicles are the safest for consumers. In doing so, automotive OEMs must spend more resources and design additional crash safety features onto their vehicles, often making them heavier in the process. As a result, negatively impacting the driving range of an electric vehicle. At Lucid Motors, through a holistic and first-principles approach, CAE simulations were used to guide the design of the Lucid Gravity to pursue highest possible crash safety ratings and battery protection while minimizing weight on the vehicle structure. By keeping the weight low, the Lucid Gravity Grand Touring was able to achieve an estimated EPA-rated range of 450 miles, which is groundbreaking for a full size 3-row electric SUV. This paper
Ng, Meng
A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes2026-01-0571To be published on 04/07/2026
Road Traffic crash statistics highlight the importance of reducing fatalities among Powered-Two-Wheeler (PTW) riders, and suggest the necessity of a robust method to evaluate PTW crashworthiness performance. The objective of this study is to clarify the relationship between impact conditions and the Head Injury Criterion (HIC) to establish a fundamental basis for determining representative crash configurations for safety. A total of 1,272 PTW-front to car-side impact simulations were conducted by using production car and PTW models. HIC was used as a metric indicating likelihood of head injury. Velocities, impact angle, and impact locations were varied to create response surfaces. The surfaces were evaluated in terms of their accuracy in identifying the representative impact conditions. In addition, head trajectories were analyzed to clarify the kinematics until head impact. The Finite Element (FE) simulations produced the following findings. - The HIC distribution by Head Impact
Yanaoka, Toshiyuki, GUNJI, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
A Comprehensive Review of System Risk in Automotive Crash Safety2026-01-0557To be published on 04/07/2026
Occupant protection has been at the forefront of risk evaluation regarding vehicle crashworthiness design. However, the vehicle is a member of a larger transportation system with varied stakeholders. This paper identifies an opportunity for assessing risk in a crash event through emerging safety science paradigms. Conventional Safety I and Safety II frameworks handle well-defined hazards but falter with uncertainty, variability, and emergent behaviors in real crashes. A comprehensive literature review was performed spanning standards, regulatory guidance, safety science, and peer-reviewed research to situate automotive crash safety risk within the Safety III paradigms. The review addresses two questions: (1) How is “risk” defined across the crash safety literature and adjacent safety science domains? and (2) What limitations arise from these definitions in practice? Findings show a dominant probabilistic framing alongside a minority of systems-oriented interpretations, with substantial
Rye, Patrick J.
Effective design method for lightweight suite of seats considering crashworthiness and cost2026-01-0493To be published on 04/07/2026
This paper presents a methodology for designing and evaluating lightweight, crashworthy aircraft seats that meet 21g crash safety standards and injury criteria. Four seat classes—economy double, economy single, single premium, and business—were developed using a modular design strategy focused on part commonality (family of parts) and manufacturability. A shared family of structural components was implemented across all seat types, with dimensional modifications applied only, when necessary, due to differences in seat width or height. In such cases, the same material systems and design principles were used to ensure consistency and reduce manufacturing complexity. The designs were evaluated using finite element simulations to verify performance under aerospace crash conditions. Each seat configuration was validated against regulatory crashworthiness criteria and injury thresholds, including pelvic, lumbar, and femur compressive forces, as well as head injury criteria (HIC) values. The
Gray, Savannah, Orr, Mathew, Shi, Yifan, Park, Taeil, Lee, Jake, Wotten, Erik, LeFrancois, Richard, Huang, Yuhao, Patel, Anuj, Kim, Hansu, Burns, Nicholas, Jalayer, Shayan, Grant, Robert, Kok, Leo, Hansen, Eric, Kim, Il Yong
Optimizing Weld Placement in Automotive Structures Using Topology and Multi-Disciplinary Approaches2026-01-0514To be published on 04/07/2026
This work presents two approaches for weld optimization aimed at reducing manufacturing cost and process time, while meeting structural performance requirements in automotive structures. The first approach uses topology optimization to identify the most efficient weld layouts. A design space is generated along mating flanges, joints, and panel interfaces, where potential weld locations are defined. Welds are treated as discrete design variables, and the topology optimization systematically evaluates their contribution to global stiffness and load path integrity. Non-critical welds, those with minimal impact on stiffness, durability, or crashworthiness, are eliminated, resulting in a minimized weld pattern that maintains structural performance. The second approach applies Multi-Disciplinary Optimization (MDO) to balance weld reduction with performance targets across multiple domains, including linear and non-linear stiffness, crashworthiness, and fatigue. Using a preprocessing tool
Koppaka, Vinaya, Yoo, Dong Yeon, Chavare, Sudeep
Crashworthiness of WC19 Wheelchairs in Horizontal Dynamic Aircraft Seating Tests09-14-02-00011/23/2026
At present, commercial air travel rules do not allow people to sit in their own wheelchairs during flight. However, airline seating often does not meet medical needs. In response to current requests to allow this seating option, we researched the crashworthiness and safety of wheelchairs for potential use in aircraft. For motor vehicle travel, many wheelchairs meet voluntary standards for crashworthiness and safety per RESNA WC19. This project assesses whether WC19-compliant wheelchairs can meet FAA aircraft seating standards when secured using 4-point tiedowns. For the FAA horizontal impact testing, computer modeling indicated that a trapezoidal sled pulse was sufficient to represent the more typical triangular pulse, and that due to the flexibility of the tiedown webbing, the effect of the simulated pitch/roll element was minimal. During the initial two horizontal impact tests, fracture of the left front wheelchair caster was observed. The remaining five wheelchairs were tested with
Klinich, Kathleen D., Manary, Miriam A., Boyle, Kyle J., Vallier, Tyler, Orton, Nichole R.
Crash Pulse Characterization for the Passenger Vehicle Fleet in India2026-26-00291/16/2026
A crash pulse is the signature of the deceleration experienced by a vehicle and its occupants during a crash. The deceleration-time plot or crash pulse provides key insights into occupant kinematics, occupant restraints, occupant loading and efficiency of the structure in crash energy dissipation. Analysing crash pulse characteristics like shape, slope, maximum deceleration, and duration helps in understanding the impact of the crash on occupant safety and vehicle crashworthiness. This paper represents the crash pulse characterization study done for the vehicles tested at ARAI as per the ODB64 test protocol. Firstly, the classification and characterization of the crash pulses is done on the basis of the unladen masses of the vehicles. The same are further analysed for suitability of mathematical waveform models such as Equivalent Square Wave (ESW), Equivalent Triangular Wave (ETW), Equivalent Sine Wave (ESW), Equivalent Haversine Wave (EHSW) as well as EDTW (Equivalent dual trapezia
Mishra, Satish, Kulkarni, Dileep, Borse, Tanmay, Mahindrakar, Rahula Ashok, Mahajan, Rahul, Jaju, Divyan
Optimization of Frontal Impact Force Scheme to Accelerate the Target Setting Process for Development of Front-End Structures in Vehicles2026-26-00011/16/2026
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full-frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, Ishan, Bhatnagar, Abhinav, Kumar, Ayush
Safer Trucks for India: Smart Tech Fusion2026-26-00311/16/2026
Commercial vehicle sector (especially trucks) has a major role in economic growth of a nation. With improving infrastructure, increasing number of trucks on roads, accidents are also increasing. As per RASSI (Road Accident Sampling System India) FY2016-23 database, commercial vehicles are involved in 42% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is over 25% of total accidents. Amongst all accident scenarios of N2 &N3, frontal impacts are the most frequent (26%) and causing severe occupant injuries. Today, truck safety development for frontal impact is based on passive safety regulations (viz. front pendulum – AIS029) and basic safety features like seatbelts. In any truck accident, it is challenging rather impossible to manage comprehensive safety only with passive safety systems due to size and weight. Accident prevention becomes imperative in truck safety development due to extremely high energy involved in front impact scenarios. The paper presents a unique
Joshi, Kedar Shrikant, Gadekar, Ganesh, Date, Atul, Koralla, Sivaprasad
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-04561/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, examined a novel configuration wherein aluminum High-pressure die cast (single HPDC part) is introduced which covers swan neck region as well as the base of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel2026-26-02951/16/2026
To meet light weighting and safety targets, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties (YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio (HER) in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays an important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light
Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh
Enhanced Integrated Cooling-Protection Plate for Battery pack Underbody Impact Resistance in Electric Vehicles2026-26-01691/16/2026
In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members. The study aims to address the dual challenges of thermal management and crash protection in electric vehicles during bottom impacts. The research evaluates the cooling efficiency and structural resilience of the proposed design through a combination of design iterations, thermal performance evaluation, and crash simulations. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. It was found that the cooling efficiency of the HV battery plates improved compared to competitor’s design, resulting in a more stable thermal environment for the battery cells. Moreover
Dusad, Sagar, Kummuru, Srikanth, Joshi, Amarja
Enhancing Energy Absorption in Rear Impact Events through Rail Extension Design and Material Variations2025-36-009612/18/2025
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
Souza Coelho Freitas, Victor de, Pereira, Romulo Franco, Souza, Daniel Souto de
Cab Roof Strength Evaluation - Quasi-Static Loading Heavy TrucksJ2422_202507 (Current)7/22/2025
This SAE Recommended Practice describes the test procedures for conducting quasi-static cab roof strength tests for heavy-truck applications. Its purpose is to establish recommended test procedures that will standardize the procedure for heavy trucks. Descriptions of the test setup, test instrumentation, photographic/video coverage, and test fixtures are included.
Truck Crashworthiness Committee
Ambulance Equipment Mount Device or SystemsJ3043_202505 (Current)5/27/2025
This SAE Recommended Practice describes the dynamic and static testing procedures required to evaluate the integrity of an equipment mount device or system when exposed to a frontal or side impact (i.e., a crash impact). Its purpose is to provide equipment manufacturers, ambulance builders, and end users with testing procedures and, where appropriate, acceptance criteria that, to a great extent, ensure equipment mount devices or systems meet the same performance criteria across the industry. Prospective equipment mount manufacturers or vendors have the option of performing either dynamic testing or static testing. Descriptions of the test setup, test instrumentation, photographic/video coverage, test fixture, and performance metrics are included.
Truck Crashworthiness Committee
Occupant Restraint and Equipment Mounting Integrity - Rear Impact Ambulance Patient CompartmentJ3044_202505 (Current)5/20/2025
This SAE Recommended Practice describes the test procedures for conducting rear impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mount testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Occupant Restraint and Equipment Mounting Integrity - Side Impact Ambulance Patient CompartmentJ2956_202505 (Current)5/20/2025
This SAE Recommended Practice describes the test procedures for conducting side impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mounting testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Development of a Generic Nearside Impact Test Fixture for Evaluating In-Vehicle Crashworthiness of Wheelchairs2025-22-00025/13/2025
Current voluntary standards for wheelchair crashworthiness only test under frontal and rear impact conditions. To help provide an equitable level of safety for occupants seated in wheelchairs under side impact, we developed a sled test procedure simulating nearside impact loading using a fixed staggered loading wall. Publicly available side impact crash data from vehicles that could be modified for wheelchair use were analyzed to specify a relevant crash pulse. Finite element modeling was used to approximate the side impact loading of a wheelchair during an FMVSS No. 214 due to vehicle intrusion. Validation sled tests were conducted using commercial manual and power wheelchairs and a surrogate wheelchair base fixture. Test procedures include methods to position the wheelchair to provide consistent loading for wheelchairs of different dimensions. The fixture and procedures can be used to evaluate the integrity of wheelchairs under side impact loading conditions.
Boyle, Kyle, Hu, Jingwen, Manary, Miriam, Orton, Nichole R., Klinich, Kathleen D.
Influence of Strain Rate Effect on Mechanical and Crashworthiness Properties of CFRP Composite Structures05-19-01-00025/6/2025
Composite materials are increasingly utilized in industries such as automotive and aerospace due to their lightweight nature and high strength-to-weight ratio. Understanding how strain rate affects the mechanical and crashworthiness properties of CFRP composites is essential for accurate impact simulations and improved safety performance. This study examines the strain rate sensitivity of CFRP composites through mechanical testing and finite element analysis (FEA). Experimental results confirm that compressive strength increases by 100%–200% under dynamic loading, while stiffness decreases by up to 22% at a strain rate of 50 s−1, consistent with trends observed in previous studies. A sled test simulation using LS-Dyna demonstrated that the CFRP crash box sustained an average strain rate of 46.5 s−1, aligning with realistic impact conditions. Incorporating strain rate–dependent material properties into the FEA model significantly improved correlation with experimental crashworthiness
Badri, Hesam, Jayasree, Nithin Amirth, Loukodimou, Vasiliki, Omairey, Sadik, Bradbury, Aidan, Lidgett, Mark, Page, Chris, Kazilas, Mihalis
Occupant Restraint and Equipment Mounting Integrity - Frontal Impact Ambulance Patient CompartmentJ2917_202505 (Current)5/3/2025
This SAE Recommended Practice describes the test procedures for conducting frontal impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mounting testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
A Low-Entry Bus Body Structure Performance under the Conditions of the New Car Assessment Program Frontal Crash Tests09-13-02-00074/9/2025
The New Car Assessment Program (e.g., US NCAP and EuroNCAP) frontal crash tests are an essential part of vehicle safety evaluations, which are mandatory for the certification of civil means of transport prior to normal road exploitation. The presented research is focused on the behavior of a tubular low-entry bus frame during a frontal impact test at speeds of 32 and 56 km/h, perpendicular to a rigid wall surface. The deformation zones in the bus front and roof parts were estimated using Ansys LS-DYNA and considered such factors as the additional mass (1630 kg) of electric batteries following the replacement of a diesel engine with an electric one. This caused stabilization of the electric bus body along the transverse axis, with deviations decreased by 19.9%. Speed drop from 56 to 32 km/h showed a reduction of the front window sill deformations from 172 to 132 mm, and provided a twofold margin (159.4 m/s2) according to the 30g ThAC criterion of R80. This leads to the conclusion about
Holenko, Kostyantyn, Dykha, Aleksandr, Koda, Eugeniusz, Kernytskyy, Ivan, Royko, Yuriy, Horbay, Orest, Berezovetska, Oksana, Rys, Vasyl, Humeniuk, Ruslan, Berezovetskyi, Serhii, Chalecki, Marek
Elevated Fracture Resistance of Q&P1180 Steel after Forming and Paint-Baking2025-01-82214/1/2025
According to several precedent studies, most of the cold-forming advanced high-strength steel (AHSS) grades can obtain reinforced yield strength from the automotive forming and paint-baking treatments without losing their fracture resistance like some aluminum alloys. Concisely, the mechanism of such behavior can be mainly attributed to the ‘Cottrell Atmospheres,’ some thermally mobilized interstitial atoms that cluster around and impede mobile dislocations during only the yielding stage of the plastic deformation but cannot continue durably enough to affect the fracture. Nevertheless, an exception, Q&P1180, was discovered from precedent studies and characterized in this work. Different from other AHSSs, this grade exhibited distinctively elevated fracture resistance and yield strength after the pre-straining and baking. Such uniqueness was speculated to be caused by 1) no soft ferrite in the microstructure and 2) the transformed fresh martensite induced by the plastic deformation
Hu, Jun, Sun, Yeting, Thomas, Grant
Application of 1.7GPa Martensitic Steel in Dash Lower Cross Member to Enhance Automotive Frontal Impact Safety2025-01-82184/1/2025
The rapid growth of electric vehicles (EVs) has led to a significant increase in vehicle mass due to the integration of large and heavy battery systems. This increase in mass has raised concerns about collision energy and the associated risks, particularly in high-speed impacts. As a consequence, crashworthiness evaluations, especially front-impact regulations, have become increasingly stringent. Crash speed between the vehicle and the Mobile Progressive Deformable Barrier (MPDB) is increasing, reflecting the growing emphasis on safety in the automotive industry. Moreover, a new frontal pole crash scenario is under consideration for future regulatory standards, highlighting the continuous evolution of crash testing protocols. To ensure occupant protection and battery safety, manufacturers have traditionally used Hot Blow Forming technology for producing closed-loop dash lower cross member components. However, this process is both costly and energy-intensive, necessitating more
Lee, Jongmin, Kim, Donghyun, Jang, Minho, Kim, Geunho, Seongho, Yoo, Kim, Kyu-Rae
Exploring Hybrid TPMS Designs for Improved Energy Absorption2025-01-87264/1/2025
Triply Periodic Minimal Surface (TPMS) structures have gained significant attention in recent years due to their excellent mechanical properties, lightweight characteristics, and potential for energy absorption in various engineering applications, particularly in automotive safety. This study explores the design, manufacturing, and mechanical performance of both general and hybrid TPMS structures for energy absorption. Three types of fundamental TPMS unit cells—Primitive, Gyroid, and IWP—were modeled using implicit functions and combined to form hybrid structures. The hybrid designs were optimized by employing Sigmoid functions to achieve smooth transitions between different unit cells. The TPMS structures were fabricated using Selective Laser Melting (SLM) technology with 316L stainless steel and subjected to quasi-static compression tests. Numerical simulations were conducted using finite element methods to verify the experimental results. The findings indicate that hybrid TPMS
Liu, Zhe, Wang, MingJie, Guo, Pengbo, Li, Youguang, Lian, Yuehui, Zhong, Gaoshuo
Material Characterization of Newly-Developed Advanced High Strength Steels for Prediction of Crash Performance2025-01-82204/1/2025
New highly ductile advanced high strength steel (AHSS) grades with tensile strength greater than 980 MPa have been developed with the aim of achieving a combination of high strength and excellent formability. The new jetQTM-Family [1, 2] offers high local and global ductility, which is expected to contribute to the improvement of vehicle crash performance. For the reliable design and management of vehicle crash performance, material modeling, including work hardening behavior and material failure strain, plays an important role in numerical simulation. Especially, the accuracy of material failure prediction is important for the development of crash performance. In this study, the fracture behaviors of 980jetQTM, 1180jetQTM, and conventional Dual-Phase (DP) steels are investigated through simple tensile and V-bending fracture tests incorporating experimental-numerical hybrid ductile fracture analysis. Based on the experimental results, the ductile fracture parameters in the Hosford
Sato, Kentaro, Sakaidani, Tomohiro, Ohnishi, Yoichiro, Paton, Adrian, Roesen, Hartwig
Crash Performance Study on High-Speed Electric Two-Wheeler Battery Enclosure2025-28-02032/7/2025
The usage of Electric Vehicles (EVs) and the annual production rate have increased significantly over the years. This is due to the development of rechargeable electrical energy storage system (battery pack), which is the main power source for EVs. Lithium-ion batteries (LIBs) pack is predominantly used across all major vehicle categories such as 2-wheelers, 3-wheelers and light commercial vehicle. LIB is one of the high energy-dense sources of volume. However, LIBs have a challenge to pose a risk of short circuits and battery pack explosions, when exposed to damage scenarios. In the present study, the controlled crash analysis is performed for various velocities ranging from 50 kmph to 72 kmph against an obstruction directly and at an offset from the wheel, so as to mimic the real-world crash of high-speed two-wheelers. The behavior of the battery enclosure is examined through evaluating the structural integrity of the battery enclosure used in a realistic two-wheeler after crash at
Venkatesan Sr, Aiyappan, Nelson, N Rino, Hariharan Nair, Adarsh
Basic Science and Art of Aircraft Wreckage Reconstruction, Second EditionR-58712/2/2024
Discover the Art and Science of Aircraft Wreckage Reconstruction "Provides excellent guidance on the documentation and reconstruction process and is a good field guide for anyone investigating an aircraft accident." ― Anthony T. Brickhouse, Embry-Riddle Aeronautical University Dive into the essential aspects of aircraft crash investigation with the new edition of Basic Science and Art of Aircraft Wreckage Reconstruction. Written by industry veteran Don Knutson, this comprehensive guide covers the intricacies of investigating crashes, the mindset needed for thorough investigations, and the step-by-step processes for on-scene reconstruction. Designed for practitioners, students, and enthusiasts alike, this book offers detailed references for further reading and research. Through generic yet real-life scenarios, Knutson provides valuable insights into aircraft crash investigations. Whether you're with a government aviation agency, a manufacturer, the military, an insurance company, law
Knutson, Donald F.
Effect of Local Ductility on Crash Performance of Automotive Structures Considering Press Forming Strain of Advanced High Strength Steels2024-01-22414/9/2024
A fundamental study on the ductility of high strength steels in crash deformation is carried out to investigate the effect of the local ductility of various materials on automobile crashworthiness, considering the prestrain induced by press forming in the manufacturing process. In this study, a newly developed 980 MPa-grade steels [1], ‘jetQTM’, is investigated to clarify its advantage in term of crashworthiness in comparison with the conventional DP (Dual Phase) and TRIP steels. Quasi-static axial crushing tests are performed to evaluate the crashworthiness of the different types of steel. Based on the experimental results, the effect of the local ductility of high-strength steel on the risk of material fracture is discussed. In this paper, a new bending test method, orthogonally reverse bending, (ORB), is proposed to simulate the fracture that occurs during crash deformation considering press-forming strain. The test method is developed using a combination of the V-bending process
Sato, Kentaro, Sakaidani, Tomohiro, Komine, Shinsuke, Wang, Fangyi, Nakagaito, Tatsuya
Multi-Material and Multi-Objective Topology Optimization Considering Crashworthiness2024-01-22624/9/2024
Recently, topology optimization (TO) has seen increased usage in the automotive industry as a numerical tool, greatly enhancing the accessibility and production-readiness of optimal, lightweight solutions. By natural extension of classic single material TO (SMTO), a wealth of research has been completed in multi-material TO (MMTO), enabling simultaneous determination of material selection and existence. MMTO is effective for linear static analyses, making use of structural responses that are continuously differentiable, giving itself to efficient gradient-based optimization engines. A structural response that is inherently nonlinear and transient, thus providing difficulty to the mainstay MMTO process, is that of crashworthiness. This paper presents a multi-objective MMTO framework considering crashworthiness using the equivalent static load (ESL) method. The ESL method uses a series of linear static sub-models to approximate the transient crashworthiness model. Then, the sub-models
Huang, Yuhao, Shi, Yifan, Morris, Zane, Teoli, Mira, Tameer, Daniel, Kim, Il Yong
A Novel Approach for Mechanical Characterization of Angle-Ply Composite Laminates2024-01-24354/9/2024
Composites made of continuous fibers generally have higher strength-to-weight ratios in fiber directions as compared to those made of discontinuous fibers. However, the latter tend to display quasi-isotropic properties which can be of advantage when directions of mechanical loading can vary. For many real-world applications such as robust design of vehicle body components for crashworthiness, impact loads are stochastic in nature both in terms of magnitude and direction. Hence, in order to realize the true potential of laminated composites with continuous fibers, instead of orthotropic laminates which are most common due to the ease of design and manufacturing, angle-ply laminates are necessary. The latter category of laminates introduce a high degree of flexibility in design options but are also simultaneously challenging in terms of mechanical characterization due to the presence of a larger number of material parameters, as compared to orthotropic laminates, with coupled normal and
Tanaya, Sushree, Deb, Anindya
Ambulance Patient Compartment Seated Occupant Excursion Zone EvaluationJ3059_202401 (Current)1/19/2024
This SAE Information Report describes the testing and reporting procedures that may be used to evaluate and document the excursion of a worker or civilian when transported in a seated and restrained position in the patient compartment of a ground ambulance when exposed to a front, side, or rear impact. Its purpose is to provide seating and occupant restraint manufacturers, ambulance builders, and end-users with testing procedures and documentation methods needed to identify head travel paths in crash loading events. This is a component level test. The seating system is tested in free space to measure maximum head travel paths. The purpose is not to identify stay out zones. Rather, the goal is to provide ambulance manufacturers with the data needed to design safer and functionally sound workstations for Emergency Medical Service workers so that workers are better able to safely perform patient care tasks in a moving ambulance. Descriptions of the test set-up, test instrumentation
Truck Crashworthiness Committee
Damage Prediction and Crashworthiness Optimization of FOBEVs in Positive Crashes for Battery Electric Vehicles2023-01-707212/31/2023
The Mobile Progressive Deformable Barrier (MPDB) is a standardized automotive crash scenario that comprehensively evaluates the safety of battery-electric vehicles (BEVs) in a crash. In an accident, the deformation pattern of the Front of Battery Electric Vehicle (FOBEV) structure, the efficiency of energy absorption, the acceleration pulse, and the degree of intrusion into the passenger compartment combine to affect the safety of the driver and passengers. In order to simulate and calculate the damage state of FOBEV in MPDB more efficiently and to construct a collision damage dataset in the entire velocity domain, a FOBEV equivalent model is proposed. The acceleration pulses from numerical simulations and impact tests were compared to verify the model’s validity. On this basis, the prediction accuracies of the Support Vector Machine model (SVM), Gaussian Process Regression model (GPR), and BP neural network model (BP) in FOBEV collision events are compared and analyzed, and BP is
Liu, Ke, Liao, Yinghua, Wang, Hongrui, Xue, Xiangdong, Liu, Changzhao
Optimization of Energy Absorption and Deformation Characteristics of Aluminium Crash Box with the Effect of Groove along with a Screw2023-28-008911/10/2023
The Crash box is the mechanical component that absorbs the impact energy by axial deformation. When an accident occurs, energy absorption and deformation play a vital role in the Automobile safety aspects, and also grooves and triggers are the ones included in the crash box for axial folding and uniform deformation. Here in this research paper, the energy absorption of kinetic energy and deformation parameter is going to be compared with the crash box with the groove at different thicknesses, also the groove is added through the vertical axis along with axial crush occurs. The modeling is done in Hyper mesh 2021 and the simulation and result validation in LS Dyna. The primary goal of this research project is to increase the crash box’s efficiency and enhance the crashworthiness and the passive safety of the passenger vehicle. It is also observed that the groove plays a vital role in reducing the acceleration transmitted to the surrounding area. The box sleeve with screw run through the
SK, Vignesh, Mayakrishnan, Jaikumar, König, Peter
Study of Vehicle-Based Metrics for Assessing the Severity of Side Impacts09-12-01-000410/30/2023
A research program has been launched in Iran to develop an evaluation method for comparing the safety performance of vehicles in real-world collisions with crash test results. The goal of this research program is to flag vehicle models whose safety performance in real-world accidents does not match their crash test results. As part of this research program, a metric is needed to evaluate the severity of side impacts in crash tests and real-world accidents. In this work, several vehicle-based metrics were analyzed and calculated for a dataset of more than 500 side impact tests from the NHTSA crash test database. The correlation between the metric values and the dummy injury criteria was studied to find the most appropriate metric with the strongest correlation coefficient values with the dummy injury criteria. Delta-V and a newly created metric T K 200 Y , which is an indicator of the kinetic energy transferred to occupants in a 200 ms time interval and in the lateral direction, were
Sadeghipour, Emad
Crashworthiness Performance of Rear Underrun Protection Device under Simulated Car Collision15-16-03-00146/6/2023
A rear underrun protection device (RUPD) plays a fundamental role in reducing the risk of running a small car beneath the rear or the side of a heavy truck because of the difference in structure heights in the event of a vehicle collision. Even in cars with five-star safety ratings, crashing into a truck with poorly designed RUPD results in a passenger compartment intrusion (PCI) more than the maximum allowable limit as per the United States (US) American National Highway Traffic Safety Administration (NHTSA) standards Federal Motor Vehicle Safety Standard (FMVSS). In this article, mild steel was used to fabricate the new designs of RUPD. The design was analyzed using finite element (FE) analysis LS-DYNA software. Simulations of a Toyota Yaris 2010 and Ford Taurus 2001 were performed at a constant speed of 63 km/h at the time of impact. The ability to prevent severe injuries in a collision with the rear side of the truck was estimated to optimize the underrun design. The new design has
Albahash, Zeid Fadel, Sharba, Mohaiman, Hasan, Bahaa Aldin Abass
Multi-Material Topology Optimization Considering Crashworthiness2023-01-00304/11/2023
There is an increasing need for lightweight structures in the transportation industry, and within these lightweight structures occupant safety is continually important to all stakeholders. Standard single and multi-material topology optimization (MMTO) techniques are effective for designing lightweight structures subjected to linear objectives and constraints but cannot consider crashworthiness. Crashworthiness must be evaluated using explicit dynamic simulation techniques, as a crash event contains geometric and material nonlinearities which cannot be captured by linear static finite element simulations. Explicit dynamic simulations prevent the calculation of sensitivity derivatives required for conventional gradient-based structural optimization strategies. This paper describes a design tool for multi-material topology optimization considering crashworthiness using the equivalent static load (ESL) method. The ESL method is used to generate linear static sub-problems which replicate
Hardman, Andrew, Sirola, Tim, Huang, Yuhao, Morris, Zane, Shi, Yifan, Kim, Il Yong, Pamwar, Manish, Sangha, Balbir
Design of a Crease Pattern for Pre-Folded Origami Structures to Improve Vehicle Crashworthiness2023-01-06374/11/2023
To promote the progressive collapse of thin-walled vehicle structures and improve their energy-absorbing capabilities, designers allocate collapse initiators such as holes, grooves, humps, and creases. The use of some traditional origami patterns in pre-folded tubes has been particularly effective in this task. However, selecting the optimal origami pattern is a complex multidimensional combinatorial problem. This paper introduces a new origami pattern that triggers an extensional progressive collapse mode in a wide range of thin-walled tubes with a square cross-section. The parameters of the proposed pattern are optimized using a multi-objective Bayesian optimization algorithm to minimize the peak crushing force and maximize the mean crushing force. The crash simulations are supported by the commercial finite element solver Radioss. The optimized pre-folded origami structure depicts extensional progressive collapse under axial loads. Compared to alternative designs, results
Chaudhari, Prathamesh, Valladares, Homero, Tovar, Andres
Crashworthiness analysis of a corkscrew rollover event2022-36-00182/10/2023
The objective of this work is to capture the final deformed shape of a vehicle after a rollover caused by a corkscrew event (ramp). With this study, it will be possible to understand the vehicle structural behavior during this event and be able to improve the vehicle safety in this specific condition. For this proposal, it will be presented a virtual methodology using available commercial CAE tools and perform a crashworthiness analysis of the desired event. The first step is to capture the dynamic event through a Multibody analysis that represents the interaction among the vehicle tire, suspension components (Springs, Dampers, Jounce Bumper, Bushings, Stabilizer Bar etc.), vehicle structural stiffness, mass, center of gravity and inertias when exposed to a corkscrew standard ramp, that initiates the rollover event. This methodology will represent with fidelity all dynamic aspects of rollover event before the vehicle touches the ground. At this point, comparison of the analysis
Tedim Terra, Rafael, Santiago, Klemer, Santos, Alex, Sobral Genaro, Piero, Capusso, Rafael
Ambulance Modular Body Evaluation - Quasi-Static Loading for Type I and Type III Modular Ambulance BodiesJ3057_202302 (Current)2/6/2023
This SAE Recommended Practice describes the test procedures for conducting quasi-static modular body strength tests for ambulance applications. Its purpose is to establish recommended test practices which standardize the procedure for Type I and Type III bodies, provide ambulance builders and end-users with testing procedures and, where appropriate, provide acceptance criteria that, to a great extent, ensures the ambulance structure meets the same performance criteria across the industry. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Load-Driven Multidisciplinary Topology Load Path Study on Car Body05-16-02-001112/14/2022
A set of multidisciplinary topology optimization (MTO) and fast validation method is discussed, which can be applied in the car body concept design stage. First, considering seven typical loading cases, optimized load path is obtained by MTO. Then an equivalent car body model is built up with new load path. In order to verify its linear and nonlinear performances quickly, original and optimized path models are established, respectively, by using macro elements. The results show that rigidity and collision performance of the optimized path are better than that of the original one. In the meantime, reduce the validation time from hours to minutes.
Zhang, Zichun, Shi, Lei
Seat Belt Comfort, Fit, and Convenience - Truck and BusJ1834_202210 (Current)10/7/2022
This SAE Recommended Practice provides design, test, and performance guidelines on the comfort, fit, and convenience for active restraint systems for heavy trucks and multipurpose passenger vehicle applications over 10000 pounds gross vehicle weight rating (GVWR). The information pertains to the forward facing seating positions.
Truck Crashworthiness Committee
Ambulance Patient Compartment Structural Integrity Test to Support SAE J3027 Compliant Litter SystemsJ3102_202206 (Current)6/21/2022
This SAE Recommended Practice describes the dynamic and static testing procedures required to evaluate the integrity of the ambulance substructure, to support the safe mounting of an SAE J3027 compliant litter retention device or system, when exposed to a frontal, side or rear impact (i.e., a crash impact). Its purpose is to provide manufacturers, ambulance builders, and end-users with testing procedures and, where appropriate, acceptance criteria that to a great extent ensure the ambulance substructure meets the same performance criteria across the industry. Prospective manufacturers or vendors have the option of performing either dynamic testing or static testing. Descriptions of the test set-up, test instrumentation, photographic/video coverage, test fixture, and performance metrics are included.
Truck Crashworthiness Committee
Ambulance Interior Storage Compartment IntegrityJ3058_202206 (Current)6/21/2022
This SAE Recommended Practice describes the dynamic testing procedures required to evaluate the integrity of patient compartment interior Storage Compartments such as cabinets, drawers, or refillable supply pouch systems when exposed to a frontal, side or rear impact (i.e., a crash impact). Its purpose is to provide component manufacturers, ambulance builders, and end-users with testing procedures and, where appropriate, acceptance criteria that, to a great extent, ensure interior Storage Compartments or systems meet the same performance criteria across the industry. Descriptions of the test set-up, test instrumentation, photographic/video coverage, test fixture, and performance metrics are included.
Truck Crashworthiness Committee
Occupant Restraint and Equipment Mounting Integrity - Rear Impact Ambulance Patient CompartmentJ3044_202206 (Historical)6/21/2022
This SAE Recommended Practice describes the test procedures for conducting rear impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mount testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Ambulance Litter Integrity, Retention, and Patient RestraintJ3027_202206 (Current)6/21/2022
This SAE Recommended Practice describes the testing procedures required to evaluate the integrity of a ground ambulance-based patient litter, litter retention system, and patient restraint when exposed to a frontal, side or rear impact. Its purpose is to provide litter manufacturers, ambulance builders, and end-users with testing procedures and, where appropriate, acceptance criteria that, to a great extent ensures the patient litter, litter retention system, and patient restraint utilizes a similar dynamic performance test methodology to that which is applied to other vehicle seating and occupant restraint systems. Descriptions of the test set-up, test instrumentation, photographic/video coverage, test fixture, and performance metrics are included.
Truck Crashworthiness Committee
Occupant Restraint and Equipment Mounting Integrity – Side Impact Ambulance Patient CompartmentJ2956_202206 (Historical)6/20/2022
This SAE Recommended Practice describes the test procedures for conducting side impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mounting testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Occupant Restraint and Equipment Mounting Integrity – Frontal Impact Ambulance Patient CompartmentJ2917_202206 (Current)6/20/2022
This SAE Recommended Practice describes the test procedures for conducting frontal impact occupant restraint and equipment mounting integrity tests for ambulance patient compartment applications. Its purpose is to describe crash pulse characteristics and establish recommended test procedures that will standardize restraint system and equipment mounting testing for ambulances. Descriptions of the test set-up, test instrumentation, photographic/video coverage, and the test fixtures are included.
Truck Crashworthiness Committee
Injury Severity Prediction Algorithm Based on Select Vehicle Category for Advanced Automatic Collision Notification2022-01-08343/29/2022
With the evolution of telemetry technology in vehicles, Advanced Automatic Collision Notification (AACN), which detects occupants at risk of serious injury in the event of a crash and triages them to the trauma center quickly, may greatly improve their treatment. An Injury Severity Prediction (ISP) algorithm for AACN was developed using a logistic regression model to predict the probability of sustaining an Injury Severity Score (ISS) 15+ injury. National Automotive Sampling System Crashworthiness Data System (NASS-CDS: 1999-2015) and model year 2000 or later were filtered for new case selection criteria, based on vehicle body type, to match Subaru vehicle category. This new proposed algorithm uses crash direction, change in velocity, multiple impacts, seat belt use, vehicle type, presence of any older occupant, and presence of any female occupant. Moreover, presence of the right-front passenger and its interaction with crash direction were considered, which affected risk prediction
Ejima, Susumu, Goto, Tsukasa, Zhang, Peng, Cunningham, Kristen, Wang, Stewart
AV/ADAS Safety-Critical Testing Scenario Generation from Vehicle Crash Data2022-01-01043/29/2022
This research leverages publicly available crash data to construct safety-critical scenarios focusing primarily on Level 3 Automated Driving Systems (ADS) safety assessment under highway driving conditions. NHTSA’s Crashworthiness Data System (CDS) has a rich dataset of representative crashes sampled from numerous Primary Sampling Units (PSUs) across the country. Each of these datasets includes the storyline, road geometry information, detailed description of actors involved in the crash, weather information, scene diagrams, crash images, and a myriad of other crash-specific details. The methodology adopted aims to generate critical scenarios from real-world driving to complement the existent regulatory tests for the validation of L3 ADS. For this work, a four-step approach was adopted to extract safety-critical scenarios from crash data. Firstly, a methodology was developed to filter crash cases relevant to the scope and resulting pdf files, and numerical crash data were downloaded
Kibalama, Dennis, Tulpule, Punit, Chen, Bo-Shian
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