Browse Topic: Impact tests

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Thoracic Injury Mechanisms Due to Front Seatback–Rear Seat Pan Interaction in Severe Rear-Impact Collisions2026-26-0005To be published on 01/16/2026
Severe rear-impact collisions can cause significant intrusion into the occupant compartment when the structural integrity of the rear survival space is insufficient. Intrusion patterns are influenced by impact configuration—underride, in-line, or override—with underride collisions channeling forces below the beltline through the rear wheels as a primary load path. This force concentration rapidly propels the rear seat-pan forward, contacting the rearward-rotating front seatback. The resulting bottoming-out phenomenon produces a forward impulse that amplifies loading on the front occupant’s upper torso, increasing the risk of thoracic injury even when the head is properly supported by the head restraint. This study analyzes a real-world rear-impact collision that resulted in fatal thoracic injuries to the driver, attributed to the interaction between the driver’s seatback and the forward-moving rear seat pan. A vehicle-to-vehicle crash test was conducted to replicate similar intrusion
Thorbole, Chandrashekhar
Development of Component Level Testing Method for Passenger Car Wheels2026-26-0504To be published on 01/16/2026
In the design of automotive wheels, safety is a crucial factor. Wheels contribute to a vehicle handling, braking and overall driving performance. Wheel are designed to withstand the weight of the vehicle and force generated during driving. It is the medium which isolates the obstacles coming from roads. Impact tests are usually performed after the wheel has been already designed and first prototypes have been produced. The test involves 90-degree free fall dynamic impact to determine the wheel resistance to deformation, cracking and overall structural failure. Its best method to captured the exact results during and post impact. These results are contributes the major role in development of automotive wheel rims. Most of the OEM’s are validating the wheels in virtual environment as FEA analysis software and LS Dyna. In this paper detailed procedure of testing of wheels at component level is presented. This work determines the development of test procedure for passenger car wheels in
Tormal, Uday Bapurao
ALLOY WHEEL RIM LINEAR CRASH VALIDATION WITH BENCH LEVEL TEST PROCEDURE2026-26-0574To be published on 01/16/2026
Crash test plays a very crucial role in determining the passenger safety along with driver safety in most modern vehicles. This has become a prominent factor for many buyers to choose a safe car. During crash test, many components tend to fail. Amongst them, the major safety critical component which hampers the drivability of a vehicle is Wheel and Tyre Assembly. With the introduction of low aspect tyres, the failure rate of these assemblies has increased. A very high importance is given to ensure these parts withstand the subjection load as it is directly related to function of vehicle. Many methods are available to test the Wheel and Tyre assembly to ensure they pass the crash criteria. We have developed a novel test method which can simulate the crash pattern in the rig/bench level. The method employs a mechanical actuator which can be operated at designated load application to ensure the assembly undergoes the anticipated failure. The process is repeated with different types of
Medaboyina, HarshaVardhan, Singh, Ram Krishnan, SUNDARAM, RAGHUPATHI, Jithendhar, Ashokan
Rear-Facing Infant Seat Structural Integrity and Crashworthiness Under Front Seatback Loading in Rear-Impact Collisions2026-26-0554To be published on 01/16/2026
Rear-facing infant seats positioned behind front outboard vehicle seats are vulnerable to loading from rearward-yielding front seatbacks during rear-impact collisions in the presence of front occupants. This seatback loading can collapse and deform the infant seat’s plastic shell, increasing the risk of head injuries to the infant occupant. Shell deformation also introduces slack into the five-point harness system, exacerbating head excursions beyond the protective boundaries of the shell and increasing the likelihood of head contact with components such as the carry handle. Current rear-facing infant seat designs typically do not account for loading imposed by the front seatback during rear-impact scenarios, resulting in weak and collapsible shell structures. Furthermore, regulatory compliance tests, such as FMVSS 213, lack provisions for evaluating rear-facing infant seats under realistic rear-impact conditions. The standard test bench does not incorporate simulated vehicle interiors
Thorbole, Chandrashekhar
Beyond ATD Dummies-Investigating Pelvic Locking and Torso Kinematics Using Human Body Models in Frontal Impact Scenarios2026-26-0002To be published on 01/16/2026
Occupant Safety systems are usually developed using anthropomorphic test devices (ATDs), such as the Hybrid III, THOR-50M, ES-2, and WorldSID. However, in compliance with NCAP and regulatory guidelines, these ATDs are designed for specific crash scenarios, typically frontal and side impacts involving upright occupants. As vehicles evolve (e.g., autonomous layouts, diverse occupant populations), ATDs are proving increasingly inadequate for capturing real-world injury mechanisms. This has led to the adoption of computational Human Body Models (HBMs), such as the Global Human Body Models Consortium (GHBMC) and Total Human Model for Safety (THUMS), which offer superior anatomical fidelity, variable anthropometry, active muscle behaviour modelling, and improved postural flexibility. HBMs can predict internal injuries that ATDs cannot, making them valuable tools for future vehicle safety development. This study uses a sled CAE simulation environment to analyze the kinematics of the HBMs
Raj, Pavan, Rao, Guruprakash, Pendurthi, Chaitanya Sagar, Nehe, Vaibhav, Chavan, Avinash
Safer Trucks for India-Smart Tech Fusion2026-26-0031To be published on 01/16/2026
Commercial vehicle sector (especially trucks) has 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) FY2016-21 database, commercial vehicles are involved in 43% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is 25% over 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 unique safety
Joshi, Kedar Shrikant, GADEKAR, GANESH, Date, Atul, Koralla, Sivaprasad
A procedure for validation of full vehicle CAE models with physical tests for passive safety applications2026-26-0411To be published on 01/16/2026
With the fast development of computational analysis tools and capacities during the past ten years, complex and substantial computer-aided engineering (CAE) simulations are now economically possible. While the cost of crash tests has risen steadily, the fidelity and complexity, which numerical simulations could address, has multiplied keeping the cost of computational analysis more stable. The use of CAE simulations complements physical testing, accelerating the product development process, reducing cost, and ensuring safe and more optimized designs. The fundamental goal of CAE is a significant reduction in the number of physical tests conducted during the product development process. However, validating the CAE model with physical tests is essential to ensure accuracy and reliability. Simulations performed using a validated CAE model could be used to make decisions like airbag deployment or high voltage shutdown without an actual physical test. This paper discusses validating an
UPENDRAN, ANOOP
GEOMETRICAL ASSESSMENT OF THE CURTAIN AIRBAG COVERAGE IN INDIAN PASSENGER VEHICLES2026-26-0021To be published on 01/16/2026
Worldwide accident statistics for passenger vehicles indicate that the number of pole side impacts usually constitute a small percentage of total accident numbers. However, the rate of fatalities in narrow object side impacts is usually the highest due to direct exposure of head with the pole/narrow objects. Curtain airbags are the most effective protective systems to prevent severe/fatal head injuries in side collisions with narrow objects such as poles or trees. One of the important parameter of curtain airbags is the inflated zone of the airbag, which decides the possibility of head exposure for occupants with different anthropometries with narrow objects. To address this issue, EuroNCAP first introduced the concept of Head Protection Device Assessment (HPDA) in 2015, which in addition to the performance requirements in dynamic test, assesses the deployed curtain airbag for its area coverage and inflated zones for various anthropometries over occupant rows. With introduction of
Jaju, Divyan, Kulkarni, Dileep, Mahajan, Rahul
Adaptive Restraints for Equitable protection.2026-26-0015To be published on 01/16/2026
Real-world crashes involve diverse occupants, but traditional restraint systems are designed for a limited range of body types considering the applicable regulations and protocols. While conventional restraints are effective for homogeneous occupant profiles, these systems often underperform in real-world scenarios with diverse demographics, including variations in age, gender, and body morphology. This study addresses this critical gap by evaluating adaptive restraint systems aligned with the forthcoming EURO NCAP 2026 protocols, which emphasize real-world crash diversity and occupant inclusivity. Through digital studies of frontal impact scenarios, we analyse biomechanical responses using adaptive restraints across varied occupant demographics, focusing on head and chest injury (e.g., Head Injury Criterion [HIC] and Chest Compression Criterion [CC]). This study used a Design of Experiments (DOE) approach to optimize occupant protection by timing the activation of these adaptive
satija, Anshul, Suryawanshi, Yuvraj, Chavan, Avinash, Rao, Guruprakash
Predictive Simulation Framework for Tyre Curb Impact Durability Assessment and Design Optimization2026-26-0396To be published on 01/16/2026
Tyre structural durability validation is a critical aspect of automotive design, considering the worsening road conditions. One of the key validation tests for assessing structural integrity is the curb impact test, which evaluates the tyre's ability to withstand sudden and concentrated impacts. Typically, this process involves physical testing of preliminary tyre samples, followed by iterative modifications to the tyre's construction to meet durability requirements. However, this approach often compromises ride performance, necessitating a more efficient and predictive methodology. To address this challenge, a frugal simulation-based prediction methodology has been developed to evaluate tyre curb impact durability before vehicle-level testing. This allows for the optimization of tyre design parameters early in the development process, ensuring structural performance while minimizing ride and handling (R&H) tuning iterations. By reducing the number of iterations, the methodology
Sundaramoorthy, Ragasruoban, LENKA., VISWESWARA
Characterization and material card calibration of PU foam under various strain rates for crash Simulation2026-26-0464To be published on 01/16/2026
Polyurethane (PU) foams are extensively utilized in automotive crash structures, seats, and interior components due to their exceptional capacity for energy absorption and dissipation during impact events. Specifically, PU foams in vehicle seats play a critical role in protecting occupants during crash scenarios by absorbing energy, distributing forces, and enhancing seatbelt performance, as well as providing countermeasures for head impact protection. The movement of the seat and the direction of the force during crash testing are inherently unpredictable. The material behavior of PU foam is captured using an isotropic, hyper-elasticity-based constitutive model available in LS-DYNA through *MAT_083. This model is designed to take into account the foam's compressibility, sensitivity to strain rates, low Poisson's ratio, and hysteresis. The characterization of a PU foam with a nominal density of 65 kg/m3 was performed using quasi-static compressive testing of 0.01/s and dynamic
Gaurav, Ashish Kumar, Krishnamoorthy, Kunju, Varatharajan, Senthilkumaran
Occupant Kinematics and injuries during high speed side impacts: An analysis of ARAI data 2016-20242026-26-0027To be published on 01/16/2026
The objective of the present study was to examine trends in occupant kinematics and injuries during side impact tests carried out on vehicle models over the period of time . Head, shoulder, torso, spine, and pelvis kinematic responses are analyzed for driver dummy in high speed side impacts for vehicle model years, MY2016-2024. Automotive Research Association of India side impact crash data is examined. The test procedure involved a 50.0 km/h moving deformable barrier (MDB) impacting the sides of stationary vehicles. Instrumented 50th-percentile male EURO SID-2 dummy was positioned in the driver seat. Occupant kinematics data, including head accelerations, Head Injury Criterion (HIC15), Torso deflections at thorax and abdominal ribs, spine accelerations at T12, and pelvis accelerations were evaluated and compared. The “peak” and “time to- peak” responses were compared across different vehicle model years. The effect of delta-V, vehicle MY, on occupant kinematics was examined. For
Mishra, Satish, Borse, Tanmay, Kulkarni, Dileep, Mahajan, Rahul, jain, aayushman
Chest Deflection mapping between HBM Connect® 50M and Humanetics ATD models for frontal impact2026-26-0010To be published on 01/16/2026
Objective Human Body Models (HBMs) are increasingly recognized by consumer protection agencies as essential tools for evaluating vehicle safety, complementing the use of traditional Anthropomorphic Test Devices (ATDs). However, HBMs are new for product development and pose challenges in connecting them with the ATDs. These challenges can be overcome if a link is established for the injury metrics between HBMs and ATDs. The study aims to develop a chest deflection mapping function between the HBM Connect® 50M (HBMC-50M) and two ATD models: THOR-50M and Hybrid III 50M for thoracic assessment in frontal impact. Method Several frontal chest loading scenarios were selected from the HBM4VT qualification catalogue (Euro NCAP technical bulletin CP 550), including hub impacts and table-top tests. Matched-pair LS-DYNA simulations were conducted with HBMC-50M and the ATD models recording peak chest deflections for developing the mapping function. In the HBMC-50M model, deflection outputs were
Velmurugan, Gopinath, Kumar PhD, Devendra, R, Udhaya Kumar, Kulavi, Pradeep, Soni, Anurag, Tejero de la Piedra, Ricardo, Fu, Stephen, Long, Teng, Arora, Tushar, Jagadish, Renuka, Shah, Chirag
Material Optimization in console armrest to comply occupant safety in crash test2026-26-0007To be published on 01/16/2026
Indian passenger vehicles sales touched an all-time high in FY25.Today’s customer expects high level of aesthetics, safety and connected features in the vehicle Interiors. This has created more diverse and demanding customer base that values interior design and quality. This has led OEMs to offer modern Indian mass car interiors with features like big infotainment system, Console Armrest…etc. The vehicle console armrest assembly is an integral part of a car's interior, designed to enhance comfort, ergonomics, and functionality for the driver and passengers. The console armrest is a complex assembly of many child parts like Armrest cushion/ sliding mechanism/ latch, locking mechanism/ hinge mechanism and storage compartment etc., Console hard plastic parts are the primary source of injuries when occupants interact with them in the event of an accident. Poorly designed armrests can contribute to flyoff of child parts in the event crash and can cause injuries to occupant. Therefore
A D, BALAMURUGA, BADDAM, SATHISH, MANGAL, GAUTAM, SINGH, DEEPAK, Shekhar, Ravi, Singh, Amit
Optimisation of frontal impact force scheme to accelerate the target setting process for development of front-end structures in vehicles.2026-26-0001To be published on 01/16/2026
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
Facilitating Virtual Testing at an Industrial Level by Simulation Data Management2026-26-0440To be published on 01/16/2026
Automotive OEMs can derive significant cost savings by reducing the quantity of physical crash tests and thereby accelerate product development, when they follow the Euro NCAP Virtual Testing guidelines. It helps in optimizing the overall vehicle development process via more efficient simulations, as well as facilitates in early adoption of new safety regulations. In this pursuit, companies must comply with strict Euro NCAP requirements, which includes transparency and traceability of virtual tests. A major challenge therein is model validation – which requires highly precise detailing and extensive use of data for accurately replicating real physics of the problem. Deploying these workflows into an existing simulation process can be a complicated and time-consuming task, particularly when integrating various simulation and testing methods. A powerful simulation and process data management system (SPDM) can thereby assist companies to automate their entire simulation process, ensures
Thiele, Marko, Sharma, Harsh
Q-Series Child Dummy FE model development and validation for child occupant safety assessment in Automotive crashes2026-26-0390To be published on 01/16/2026
The Ministry of Road Transport and Highways (MoRTH), Government of India has established BHARAT NCAP to provide a fair, meaningful, and objective assessment of the crash safety performance of cars. This program evaluates vehicles across three key areas, including Child Occupant Protection (COP). A critical component of the COP assessment involves dynamic testing using Q-series child dummies representing a 1½-year-old (Q1.5) and a 3-year-old child (Q3). As per the BHARAT NCAP protocol these dummies are placed in the second-row outboard seating position within Child Restraint Systems (CRSs) and subjected to two primary dynamic impact tests: Offset Deformable Barrier (ODB) conducted at speed of 64 km/hr. and Mobile Deformable Barrier (MDB) Side Impact tests conducted at 50 km/hr. The dynamic assessment of these child dummies is primarily focused on the head, neck, and chest regions to evaluate the effectiveness of the CRSs and overall vehicle safety system in protecting young occupants
Khopekar, Maria, Lakshminarayana, Apoorva, Mohan, Pradeep, Kurkuri, Mahendra
Improvement study of Style steel wheel durability in Multiple pothole impacts2026-26-0539To be published on 01/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads - a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, CHANDRAMOHAN, C, Santhosh
Analysis of Road Accident Statistics for Females in India and Gaps in Safety Regulations2026-26-0020To be published on 01/16/2026
This paper investigates the current state of road safety for female occupants in India, with a particular focus on road accident statistics and the gaps in safety regulations. According to the Road Accident in India 2022 report by the Ministry of Road Transport and Highways (MoRTH), female occupants constitute 16% of passenger car fatalities. Leveraging a comprehensive dataset of 525 passenger car accidents involving at least one female occupant from the Road Accident Sampling System – India (RASSI), this study evaluates the severity and patterns of injuries sustained by female drivers and passengers. The analysis identifies critical shortcomings in existing safety measures, particularly in addressing anatomical disparities and male-centric safety designs. Gender-disaggregated injury trends reveal heightened vulnerabilities for women in crash scenarios, including disproportionate risks to the chest, neck, and pelvis. Current regulatory frameworks rely on crash test dummies developed on
Ayyagari, Chandrashekhar, G, Santhosh Kumar, Rao, Guruprakash
Comparison of Bharat NCAP Crash test scenarios with real road accidents in India2026-26-0024To be published on 01/16/2026
This study is conducted to analyse the significance of BNCAP crash test protocol in the real road accidents in India. Accident data from on-the-spot investigation (Road Accident Sampling System India) and Government of India’s, Ministry of Road Transport and Highways official road accident statistics 2023 is used together to understand the real road accidents in India. The current BNCAP crash test protocol is compared against the real road accidents and the frequency of the same in discussed in this paper. A seven-step calculation method is developed to analyse real accidents together with existing crash tests by using similar crash-characteristics like impact area, overlap and direction of force. This method makes the real accident comparable with the corresponding crash test by calculating the impact energy during the collision between the real accident and a collision under crash test conditions. Relevant parameters in real accidents that significantly influence the test scenario
Moennich, Joerg, Lich, Thomas, Kumaresh, Girikumar
Investigation of the Effect of Rotation Speed and Post-Weld Heat Treatment on Mechanical Properties and Structure of Friction Stir Welding AA6061 Joints05-19-02-001609/25/2025
This study aims at examining the effect of tool rotational speed on the microstructural and mechanical properties of friction stir welded joints of AA6061 aluminum alloy, both pre- and post-heat treatment. The quality of the joints was assessed initially through tensile, hardness, and charpy impact tests, as well as microscopic observations. During the second stage, solid solution heat treatments were conducted at 535°C, followed by aging on additional specimens welded at identical speeds. The latter underwent hardness tensile tests and microscopic examinations. A comprehensive assessment of the outcomes from various tests validated the influence of metallurgical phenomena, including recrystallization, precipitation, and structural defects on overall resistance. The results showed an improvement in strength, ductility, and impact energy was observed in the case of welding at high rotation speed (1400 rpm). At the same speed, ductility almost doubled after post-weld heat treatment
Bouchelouche, Fatima, Debih, Ali, Ouakdi, Elhadj
Performance Specifications for Anthropomorphic Test Device TransducersJ2570_202506 (Current)06/30/2025
This SAE Recommended Practice defines the minimum performance specifications for sensors used within anthropomorphic test devices (ATDs) when performing impact tests per SAE J211. It is intended that any agency proposing to conduct tests in accordance with SAE J211 shall be able to demonstrate that the transducers they use would meet the performance requirements specified in this document.
Safety Test Instrumentation Standards Committee
Traumatic Head and Brain Injuries in Helmeted Motorcycle Crashes2025-22-000606/27/2025
This study presents an analysis of 364 motorcycle helmet impact tests, including standard certified full-face, open-face, and half-helmets, as well as non-certified (novelty) helmet designs. Two advanced motorcycle helmet designs that incorporate technologies intended to mitigate the risk of rotational brain injuries (rTBI) were included in this study. Results were compared to 80 unprotected tests using an instrumented 50th percentile Hybrid III head form and neck at impact speeds ranging from 6 to 18 m/s (13 to 40 mph). Results show that, on average, the Head Injury Criterion (HIC) was reduced by 92 percent across certified helmets, compared to the unhelmeted condition, indicating substantial protection against focal head and brain injuries. However, findings indicate that standard motorcycle helmets increase the risk of AIS 2 to 5 rotational brain injuries (rTBI) by an average of 30 percent compared to the unprotected condition, due to the increased rotational inertia generated by
Lloyd, John
Evaluation of Occupant Injury Risk in a Transport Aircraft Crash Test Environment02-18-02-001105/16/2025
Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) previously conducted a full-scale crash test of a Fokker F28 MK1000 aircraft to study occupant injury risks. The goal of the current study was to investigate the injury predictions of the Global Human Body Models Consortium (GHBMC) and Total Human Model for Safety (THUMS) occupant models in the tested aircraft crash condition and explore possible utilization of both human body models (HBMs) in this context. Eight crash conditions were simulated utilizing each of the models. The HBMs were positioned in two postures, a neutral upright posture with hands resting on the legs and feet contacting the floor and a braced posture with head and hand contact with the forward seat back. Head and neck injury metrics and lumbar vertebra axial force were calculated and compared for all simulations. Both HBMs reported similar kinematic responses in the simulated impact conditions. However, the GHBMC
Jones, Nathaniel, Putnam, Jacob, Untaroiu, Costin Daniel
Development of a Generic Nearside Impact Test Fixture for Evaluating In-Vehicle Crashworthiness of Wheelchairs2025-22-000205/13/2025
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 Structures05-19-01-000205/06/2025
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
Crash Performance Improvement: The Impact of Engine Mount Crash Plates on Achieving a 5-Star Safety Rating2025-01-008505/05/2025
Electric vehicles (EVs) differ from internal combustion engine (ICE) vehicles in that they lack a conventional engine and feature an electric drive unit, leading to distinct dynamic behaviours in the powertrain. Additionally, the arrangement of auxiliary components in EVs often differs from that in traditional ICE vehicles, which can sometimes significantly impact safety ratings. This paper examines a case study of a critical failure during a crash test, where displacement of an engine mount arm caused substantial structural intrusion and reduced the vehicle’s safety rating. To address this issue and enhance crashworthiness, a “crash plate” was designed and integrated into the mount system. This solution effectively constrained the mount arm’s movement during impact, preventing the intrusion observed in previous tests. The paper provides a detailed analysis of the crash plate’s dimensions and its relationship to the engine mount, demonstrating its potential for broader application in
Hazra, Sandip, Khan, Arkadip, Mohare, Gourishkumar
A Low-Entry Bus Body Structure Performance under the Conditions of the New Car Assessment Program Frontal Crash Tests09-13-02-000704/09/2025
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
Analysis and Comparison of Metrics to Assess Submarining Behavior with the Hybrid III 5th Percentile Dummy in the Rear Seat2025-01-871104/01/2025
Real-world data show that abdominal loading due to a poor pelvis-belt restraint interaction is one of the primary causes of injury in belted rear-seat occupants, highlighting the importance of being able to assess it in crash tests. This study analyzes the phenomenon of submarining using video, time histories, and statistical analysis of data from a Hybrid III 5th female dummy seated in the rear seat of passenger vehicles in moderate overlap frontal crash tests. This study also proposes different metrics that can be used for detecting submarining in full-scale crash tests. The results show that apart from the high-speed videos, when comparing time-series graphs of various metrics, using a combination of iliac and lap belt loads was the most reliable method for detecting submarining. Five metrics from the dynamic sensors (the maximum iliac moment, maximum iliac force drop in 1 ms, time for 80% drop from peak iliac force, maximum pelvis rotation, and lumbar shear force) were all
Jagtap, Sushant R, Jermakian, Jessica S, Edwards, Marcy A
Application of 1.7GPa Martensitic Steel in Dash Lower Cross Member to Enhance Automotive Frontal Impact Safety2025-01-821804/01/2025
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
Advanced Driver Assistance Systems (ADAS): Assessing the Efficacy of Non-Impact Testing for Evaluating the Performance of Frontal Collision Mitigation Technology2025-01-805604/01/2025
As Automatic Emergency Braking (AEB) systems become standard equipment in more light duty vehicles, the ability to evaluate these systems efficiently is becoming critical to regulatory agencies and manufacturers. A key driver of the practicality of evaluating these systems’ performance is the potential collision between the subject vehicle and test target. AEB performance can depend on vehicle-to-vehicle closing speeds, crash scenarios, and nuanced differences between various situational and environmental factors. Consequently, high speed impacts that may occur while evaluating the performance of an AEB system, as a result of partial or incomplete mitigation by an AEB activation, can cause significant damage to both the test vehicle and equipment, which may be impractical. For tests in which impact with the test target is not acceptable, or as a means of increasing test count, an alternative test termination methodology may be used. One such method constitutes the application of a late
Kuykendal, Michelle, Easter, Casey, Koszegi, Giacomo, Alexander, Ross, Paradiso, Marc, Scally, Sean
Overview of Seat Design Changes and Performance2025-01-872904/01/2025
The National Highway Traffic Safety Administration (NHTSA) published an Advance Notice of Proposed Rulemaking (ANPRM) to update the Federal Motor Vehicle Safety Standard (FMVSS) 207. Part of the ANPRM is to assess the merit of conducting quasi static body block seat pull tests and conducting FMVSS 301 rear crash tests at 80 km/h or higher with a 95th percentile ATD lap-shoulder belted in the front seats and limiting seatback deflection to 15 to 25 degrees. Prior to updating regulations, it is important to understand the seating design history and implications. This study was conducted to provide a historical background on seat design and performance using literature and test data. One objective was to first define the terminology used to describe occupant kinematics in rear crashes. Secondly, seat design evolution is then discussed. Third, test methods and test results were summarized, and fourth, the field performance are synopsized and discussed with respect to 2nd row occupant
Parenteau, Chantal, Burnett, Roger, Davidson, Russell
Predicting Head Injury Criterion in Real-World Frontal Impacts2025-01-870904/01/2025
Research on modeling head injury metrics and head acceleration waveforms from real-world collisions has been limited compared to vehicle crash pulses. Prior studies have used rectangular, triangular, polynomial, half-sine, and haversine pulse functions to model vehicle crash pulses and have employed more complex approximations for head injury metrics. This study aimed to develop a method to predict 15 ms Head Injury Criterion (HIC15) in frontal passenger vehicle impacts using these simple pulse functions, where only occupant peak head acceleration and head impact duration are known. Vehicle crash tests from the New Car Assessment Program (NCAP) were selected for frontal impacts that included driver occupants. Head acceleration and shoulder belt load channels of Hybrid III 50th percentile male anthropomorphic test devices were collected and separated for training a set of ratios and testing their performance. Rectangular, triangular, quadratic, half-sine, and haversine pulse functions
Westrom, Clyde, Tanczos, Rachel, Adanty, Kevin, Shimada, Sean
Parameter Calibration Method of Johnson-Cook Constitutive Model based on Tensile and Compression Tests2025-01-824204/01/2025
In new energy vehicles, aluminum alloy has gained prominence for its ability to achieve superior lightweight properties. During the automotive design phase, accurately predicting and simulating structural performance can effectively reduce costs and enhance efficiency. Nevertheless, the acquisition of accurate material parameters for precise predictive simulations presents a substantial challenge. The Johnson-Cook model is widely utilized in the automotive industry for impact and molding applications due to its simplicity and effectiveness. However, variations in material composition, processing techniques, and manufacturing methods of aluminum alloy can lead to differences in material properties. Additionally, components are constantly subjected to complex stress states during actual service. Conventional parameter calibration methods primarily rely on quasi-static and dynamic tensile tests, offering limited scope in addressing compression scenarios. This paper proposes an inversion
Kong, Deyu, Gao, Yunkai
High-Speed FCW & AEB Testing of Tesla Model 3's Across Software Updates2025-01-869504/01/2025
A total of 148 tests were conducted to evaluate the Forward Collision Warning (FCW) and Automatic Emergency Braking (AEB) systems in five different Tesla Model 3 vehicles between model years 2018 and 2020. The testing occurred across four calendar years from 2020 to 2024. These tests involved testing against stationary vehicle targets, including a foam Stationary Vehicle Target (SVT), a Deformable Stationary Vehicle Target (DSVT), a live vehicle with brake lights, and a SoftCar360 designed for high-speed impact tests. The evaluations were conducted at speeds of 35, 50, 60, 65, 70, 75, and 80 miles per hour (mph) during both daytime and nighttime conditions. The analysis encompassed comparisons of Time to Collision (TTC) at FCW, TTC at AEB, and emergency braking deceleration magnitudes across the different software versions. Testing of the Traffic Aware Cruise Control (TACC) system was also conducted against a stationary target in the Tesla’s lane at a speed of 80 mph. The findings
Harrington, Shawn, Nagarajan, Sundar Raman
Damage Analysis of Traction Battery For New Energy Vehicle Based on Bottom Impact2025-01-812504/01/2025
As the high-quality development of the new energy vehicle (NEV) and traction battery industries, the safety of traction batteries has become a global focus. Typically mounted at the bottom of NEVs, traction battery systems are particularly vulnerable to mechanical damage caused by bottom impacts, posing serious safety risks. This study investigates the damage sustained by NEV traction battery systems during bottom impact collisions, using computer tomography analysis to detail the damage mechanisms. The findings provide valuable data to enhance the safety and protective performance of traction batteries under such scenarios.
Yan, Pengfei, Wang, Fang, Ma, Tianyi, Han, Ce, He, Gaiyun
Barrier Weight Prediction for Vehicle Compatibility in North America Market Using Finite Element Analysis2025-01-862104/01/2025
The proliferation of the electric vehicle (EVs) in the US market led to an increase in the average vehicle weight due to the assembly of the larger high-voltage (HV) batteries. To comply with this weight increase and to meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity (stiffness) has increased substantially. This increased stiffness in the larger vehicles (Large EV pickups/SUVs) may have a significant impact during collision with smaller vehicles. To address this issue, it is necessary to consider adopting a vehicle compatibility test like Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) for the North American market as well. This study examines the influence of mass across vehicle classes and compares the structural variations for each impact class. The Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) protocol referenced for this analysis. Our evaluation
Kusnoorkar, Harsha, Koraddi, Basavaraj, Guerrero, Michael, Sripada, Venu Vinod, Tangirala, Ravi
Comprehensive Injury Assessment of Reclined Occupants across Varied Seat Configurations with the THUMS Human Body Model2025-01-873904/01/2025
The development of autonomous driving technology will liberate the space in the car and bring more possibilities of comfortable and diverse sitting postures to passengers, but the collision safety problem cannot be ignored. The aim of this study is to investigate the changes of injury pattern and loading mechanism of occupants under various reclined postures. A highly rotatable rigid seat and an integrated three-point seat belt were used, with a 23g, 50kph input pulse. Firstly, the sled test and simulation using THOR-AV in a reclined posture were conducted, and the sled model was verified effective. Based on the sled model, the latest human body model, THUMS v7, was used for collision simulation. By changing the angle of seatback and seat pan, 5 seat configurations were designed. Through the calculation of the volunteers' pose regression function, the initial position of THUMS body parts in different seat configurations was determined. The responses of human body parts were output
Yang, Xiaoting, Wang, Qiang, Liu, Yu, Fei, Jing, Wang, Peifeng, Li, Zhen, Bai, Zhonghao
The Influence of out-of-Position Displacement during Emergency Braking on Occupant Whiplash Injury in Subsequent Rear-End Collisions2025-01-872004/01/2025
In the pre-crash emergency braking scenario, the occupant inside the vehicle will move forward due to inertia, deviating from the standard upright seating position for which conventional restraint systems are designed. Previous studies have mainly focused on the influence of out-of-position (OOP) displacement on occupant injuries in frontal collisions, and provided solutions such as active pretensioning seatbelts (APS). But little attention has been paid to the influence of OOP on whiplash injury during a subsequent rear-end collision. To investigate the forward OOP impact on whiplash injuries and the effectiveness of APS in this accident scenario, a vehicle interior model with an active human body model (AHBM) was setup in the MADYMO simulation platform. Different braking strengths (0.8g and 1.1g), APS triggering times (from 0.2s before to 0.2s after the braking initiation) and pretensioning forces (from 100N to 600N) were input to the simulation matrix. The occupant’s forward OOP
Fei, Jing, Qiu, Hang, Wang, Peifeng, Liu, Yu, Cheng, James Chih, Zhou, Qing, Tan, Puyuan
Design of an Integrated Crash Safety Test Scenario: Rear-End Collision in SUBSEQUENCE of Emergency Braking2025-01-874704/01/2025
The integrated vehicle crash safety design provides longer pre-crash preparation time and design space for the in-crash occupant protection. However, the occupant’s out-of-position displacement caused by vehicle’s pre-crash emergency braking also poses challenges to the conventional restraint system. Despite the long-term promotion of integrated restraint patterns by the vehicle manufacturers, safety regulations and assessment protocols still basically focus on traditional standard crash scenarios. More integrated crash safety test scenarios and testing methods need to be developed. In this study, a sled test scenario representing a moderate rear-end collision in subsequence of emergency braking was designed and conducted. The bio-fidelity of the BioRID II ATD during the emergency braking phase is preliminarily discussed and validated through comparison with a volunteer test. The final forward out-of-position displacement of the BioRID II ATD falls within the range of volunteer
Fei, Jing, Wang, Peifeng, Qiu, Hang, Liu, Yu, Shen, Jiajie, Cheng, James Chih, Zhou, Qing, Tan, Puyuan
Occupant Responses in High-Speed Rear Sled Tests: Focus of Initial Position, Seat Strength and ATD Size2025-01-873104/01/2025
The National Highway Safety Administration (NHTSA) recently published an Advanced Notice of Proposed Rulemaking (ANPRM) to evaluate seat performance in rear impacts [1]. The ANPRM was issued partially in response to two petitions requesting an increase in seatback strength requirements and high-speed testing with various size Anthropometric Test Devices (ATDs). To better understand the effect of these requests, this study evaluates ATD responses with two high-speed rear sled conditions, three occupant sizes and various seat designs. Seat designs varied from modern conventional seats with yielding properties to stronger and stiffer seats represented by seat integrated restraint (SIR) designs, and rigidized SIR seats. Twenty-four rear sled tests were analyzed. The tests were matched by crash severity, seat designs (strength), ATD sizes and initial postures (nominal/in-position, leaned forward and leaned outboard). The test data and videos were reviewed to identify time coinciding with
Parenteau, Chantal, Burnett, Roger
The Biomechanical Effects of Neck and Back Cushion / Pillow / Support Devices in Low-Speed Rear Impacts2025-01-872804/01/2025
There are numerous commercially available neck and back support/cushion/pillow devices which are commonly attached to seats by vehicle owners. To our knowledge, there has been no published research on the biomechanical effects of these devices in low-speed rear impacts. To address this, a series of 54 simulated low-speed rear impact tests were conducted using a validated remote-controlled crash sled system. All tests utilized an instrumented BioRID II rear impact anthropomorphic test device (ATD) restrained using a 3-point seatbelt system in a 2018 Toyota Camry LE driver’s seat. Two delta-V ranges were used: a lower range from 7.2 to 8.0 kph (4.5 to 5.0 mph) and a higher range from 10.5 to 11.3 kph (6.5 to 7.0 mph). Six neck only devices, one combination neck and back device, and three back only devices were assessed. Two tests per delta-V range for each device and each device adjustment position were conducted and compared against five reference tests without any devices at each delta
Phan, Andrew, Gross, Jamie, Umale, Sagar, Crowley, Shannon, Glasser, Gabriel, Furbish, Christopher
Analysis of Occupants' Responses in Frontal Sled Tests under a Reclined Rigid Seat Environment2025-01-873404/01/2025
With the increasing adoption of Zero-Gravity Seats in intelligent cockpits, there is a growing concern over the safety of occupants in reclined postures during collisions. The newly released anthropomorphic test device (ATD), THOR-AV, has modified the neck, spine, and pelvis structures to better match reclined postures. This study aims to investigate the changes in kinematic response and injury metrics for occupants in reclined postures, through high-speed frontal sled tests utilizing the THOR-AV. The tests were conducted using an adjustable rigid seat with a zero-gravity characteristic and an integrated three-point seat belt. Six tests were performed across four seat configurations: Standard, Semi-Reclined, Reclined, and Zero-gravity postures. The input acceleration pulse for these tests was derived from the equivalent double trapezoidal waveform of the Mobile Progressive Deformable Barrier (MPDB) test. Data from sensors and high-speed video were collected for analysis. The results
Wang, Qiang, Liu, Yu, Fei, Jing, Yang, Xiaoting, Wang, Peifeng, Bai, Zhonghao
Design Methodology and Evaluation Techniques for Pelvic Pusher Energy Absorption Pad2025-01-861504/01/2025
Pelvic pusher energy absorption pad in a vehicle saves the occupant from pelvic injuries in the event of a crash, especially side or pole crash. This pelvic pusher pad plays a crucial role in absorbing the impact energy from the body side and minimizing the impact to the occupant. Positioning of pelvic pusher pad with respect to occupant manikin position and torso angle, stiffening criteria for the energy absorption pad, maximum force and energy absorption target setting methodology and evaluation methods through CAE and part level physical validations are all discussed in detail. Pelvic pusher pad are of various types such as EPP moulded, blow moulded or injection moulded and the criteria differ for each type. For EPP moulded type, based on the EPP grade, S-S Graph gets converted to F-S Graph and validated accordingly. F-S Graph for a test vehicle is generated through sled test where the sled is made to impact the pelvis of ES2 Dummy at a constant velocity and the F-S Graph is
S M, Rahul, d, Anantha, Kakani, Phani Kumar, Malliboina, Mahendra
A New Inverse Method for the Determination of Mechanical Properties of an Angle-Ply Composite Laminate by the CLPT2025-01-832304/01/2025
Utilization of fiber-reinforced composite laminates to their full potential requires consideration of angle-ply laminates in structural design. This category of laminates, in comparison with orthotropic laminates, imposes an additional degree of challenge, due to a lack of material principal axes, in determination of elastic laminate effective properties if the same has to be done experimentally. Consequentially, there is a strong inclination to resort to the usage of “CLPT” (Classical Laminated Plate Theory) for theoretically estimating the linear elastic mechanical properties including the cross-correlation coefficients coupling normal and shear effects. As an angle-ply laminate is architecturally comprised of layers of biased orthotropic laminas (based on unidirectional or woven bidirectional fibers), an essential prerequisite for the application of CLPT is an a-priori knowledge of elastic mechanical properties of a constituent lamina. It is natural to expect that the properties of
Tanaya, Sushree, Deb, Anindya
Structural Seam Weld Optimization with Efficient Approach of DFSS2025-01-824804/01/2025
In automotive engineering, seam welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weaker material link for durability and impact loads, which are measured by lab-controlled durability and crash tests, as well as real-world vehicle longevity. Consequently, designing robust welded components while optimizing for material performance is often prioritized as engineering challenge. The position, dimensions, material, manufacturing variation, and defects all affect the weld quality, stiffness, durability, impact, and crash performance. In this paper, the authors present best practices based on studies over many years, a rapid approach for optimizing welds, especially seam welds, by adopting Design For Six Sigma (DFSS) IDDOV (Identify, Define, Develop, Optimization, and Verification) discrete optimization approach. We will present the case testimony to show the approach throughout
Qin, Wenxin, Li, Fan, Pohl, Kevin J., Pentapati, Venkat
Development and Validation of a Rear Head Surround Foam Performance Specification for Stock Car Racing2025-01-835304/01/2025
Over the last two decades many improvements have been made in stock car racing driver safety. One of these is the head surround, which is rigidly secured to and an integral part of the NASCAR (National Association for Stock Car Auto Racing, LLC) seating environment and serves as an effective restraint for head protection during lateral and rear impacts. However, previous head impact material specifications were optimized for moderate to severe impacts and did not address low severity impacts that occur frequently during typical driving, such as race restart vehicle nose-to-tail contact. This study focused on developing a test methodology for comprehensive evaluation of rear head surround materials for low, moderate and severe impacts. Specifically, this study aimed to formulate a specification that maintains previous material performance during high speed impacts, while decreasing head accelerations at low speed impacts. Quasi-static and dynamic drop tower testing of sample materials
Gray, Alexandra N., Harper, Matthew G., Mukherjee, Sayak, Patalak, John P., Gaewsky, James
A Sled Test Methodology for 25% Offset Crash Tests2025-01-873704/01/2025
Sled crash tests are an important tool to develop automotive restraint systems. Compared with full-scale crash tests, the sled test has a shorter development cycle of the restraint system and lower cost. The objective of the present study is to create a cost-effective sled test methodology, calculate the optimal static yaw angle and loading curves, and analyze the motion response and injuries of the dummy in the small overlap crash test. The effectiveness of the proposed methodology was verified under two typical small overlap frontal crash modes: “energy-absorption” and “sideswipe”. The results show that with the calculated yaw angle α, the HIC was different from the small overlap crash model, but all remaining indices were within 5% of the injury criteria. All International Organization for Standardization (ISO) values between the combined accelerations of all parts of the dummy and those of the basic model exceeded 0.75, and some values were above 0.8. Therefore, the proposed sled
Yu, Liu, Chen, Jianzhuo, Wan, Ming Xin, Fan, Tiqiang, Yang, Peilong, Nie, Zhenlong, Ren, Lihai, Cheng, James Chih
Aggregation of Cervical Loads in Rear Impact Crash Tests and Comparison to Activities of Daily Living2025-01-870804/01/2025
Peak upper and lower neck load data from rear impact crash testing were reviewed, aggregated, and analyzed from over 1,800 tests of existing peer-reviewed literature and research as well as available testing conducted by the Insurance Institute for Highway Safety (IIHS) and the National Highway Traffic Safety Administration (NHTSA). Both human volunteers and anthropomorphic test devices (ATDs) were subjects of the reviewed studies and testing. Peak upper and lower neck axial forces (compression and tension), sagittal shear forces, and sagittal moments (flexion and extension) from available crash testing were reported and analyzed as functions of measured change in velocity (delta-V) ranging from approximately 3 to 60 km/h (1.9 to 37 mph). This load data was then further analyzed for possible trends amongst various testing conditions, such as seat type, ATD used, and subject seating position within the vehicle chassis and seat to develop a simple linear model. The linear regressions
Kazmierczak, Alex, Umale, Sagar, Visalli, Alyssa, Webb, Ella, Kashdan, Aryeh, Randles, Bryan, Welcher, Judson
GA-BP Neural Network-Based Prediction of Impact Resistance in Electric Vehicle Charging Piles05-18-04-002803/27/2025
Impact resistance is crucial for assessing charging pile safety and reliability. This study proposes a prediction model, called GA-BP neural network, which achieved prediction errors below 5% and reduced computation time by over 95% in comparison to finite element analysis (FEA). Initially, the charging pile impact test platform is constructed, and a matching finite element simulation model is developed. The correctness of the simulation model is then verified by integrating the experimental findings. Furthermore, the Latin hypercube approach is used to create 200 sets of simulation schemes, and using the Python programming language, the impact resistance performance indicators of charging piles are automatically collected. Next, a genetic algorithm is used to optimize the initial weight and bias of the BP neural network, lastly, fine-tune the hyperparameters in the neural network to develop a prediction model for the impact resistance performance of the charging pile. The GA-BP model
Jiang, Bingyun, Hu, Peng, Liu, Zhenyu, Yuan, Pengfei, Liu, Hui
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