• Steel and Composite Structures
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• v.24 no.3
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• pp.351-358
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• 2017

Due to the increasing competition, automotive manufacturers have to manufacture highly safe and light vehicles. The parts which make up the body of the vehicle and absorb the energy in case of a crash, are usually manufactured with sheet metal forming methods such as deep drawing, bending, trimming and spinning. The part may get thinner, thicker, folded, teared, wrinkled and spring back based on the manufacturing conditions during manufacturing and the type of application methods. Transferring these effects which originate from the forming process to the crash simulations that are performed for vehicle safety simulations, makes accurate and reliable results possible. As a part of this study, firstly, the one-step and incremental sheet metal forming analysis (deep drawing + trimming + spring back) of vehicle front bumper beam and crash boxes were conducted. Then, crash performances for cases with and without the effects of sheet metal forming were assessed in the crash analysis of vehicle front bumper beam and crash box. It was detected that the parts absorbed 12.89% more energy in total in cases where the effect of the forming process was included. It was revealed that forming history has a significant effect on the crash performance of the vehicle parts.

• Composites Research
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• v.31 no.1
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• pp.37-41
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• 2018

The aim of the current work is to characterise a piecewisely-integrated composite bumper beam based on the IIHS bumper crash protocol. IIHS bumper crash FE analysis for an aluminium type bumper beam was carried out to get the information about the dominant loading types at several regions in the bumper beam during crash. In the meantime, robust stacking sequences against tension and compression have been searched for using FE analysis of a coupon type model. After determining most effective stacking sequences for tension and compression, three-point bending simulation was preliminarily carried out to investigate the combination performance of them. Finally, IIHS bumper crash FE analysis for the piecewisely-integrated composite bumper beam, which consisted of the combination of tension effective stacking sequence and compression efficacious stacking sequence, was conducted and the result was compared with other types of composite bumper beams. It was found that the newly suggested piecewisely-integrated composite bumper beam showed superior crashworthy behaviour to those of uni-modal stacking sequence composite bumper beams.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.226-232
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• 2000

This paper develops a finite element model for studying the crashworthiness analysis of a mid-size truck. A simulation for a truck frontal crash to a rigid barrier using the model is performed with PAM-CRASH installed in super computer SP2. Full vehicle model is composed of 86467 shell elements, 165 beam elements and 98 bar elements, and 86769 nodes. The model uses four material model such as elastic, elastic-plastic(steel), rigid and elastic-plastic(rubber) material model which are in PAM-CRASH. Frame and suspension system are modeled with 28774 shell elements and 31412 nodes. Cab is modeled with 34680 shell elements and 57 beam elements, and 36254 nodes. Bumper is modeled with 2262 shell elements, and 2508 nodes. Axle, steering shaft, etc are modeled using beam or bar elements. Mounting parts are modeled using rigid bodies. Bodies are interconnected using nodal constrains or joint options. To verify the developed model, frontal crash test with 30mph velocity to a rigid barrier is carried out. In the crash test, vehicle pulse at lower part of b-pillar is measured, and deformed shapes of frame and driver seat area are photographed. Those measured vehicle pulse and photographed pictures are compared those from the simulation to verify the developed finite element model.

• International Journal of Automotive Technology
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• v.7 no.3
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• pp.329-336
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• 2006

The resistance spot-welded region in most current finite element crash models is characterized as a rigid beam at the location of the welded spot. The region is modeled to fail with a failure criterion which is a function of the axial and shear load at the rigid beam. The calculation of the load acting on the rigid beam is important to evaluate the failure of the spot-weld. In this paper, numerical simulation is carried out to evaluate the calculation of the load at the rigid beam. At first, the load on the spot-welded region is calculated with the precise finite element model considering the residual stress due to the thermal history during the spot welding procedure. And then, the load is compared with the one obtained from the model used in the crash analysis with respect to the element size, the element shape and the number of imposed constraints. Analysis results demonstrate that the load acting on the spot-welded element is correctly calculated by the change of the element shape around the welded region and the location of welded constrains. The results provide a guideline for an accurate finite element modeling of the spot-welded region in the crash analysis of vehicles.

• Transactions of the Korean Society of Automotive Engineers
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• v.14 no.2
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• pp.174-183
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• 2006

The resistance spot-welded region in most current finite element crash models is characterized as a rigid beam at the location of the welded spot. The region is modeled to fail with a failure criterion which is a function of the axial and shear load at the rigid beam. The role of this rigid beam is simply to transfer the load across the welded components. The calculation of the load acting on the rigid beam is important to evaluate the failure of the spot-weld. In this paper, numerical simulation is carried out to evaluate the calculation of the load at the rigid beam. The load calculated from the precise finite element model of the spot-welded region considering the residual stress due to the thermal history during the spot welding procedure is regarded as the reference value and the value of the load is compared with the one obtained from the spot-welded model using the rigid beam with respect to the element size, the element shape and the number of imposed constraints. Analysis results demonstrate that the load acting on the spot-welded element is correctly calculated by the change of the element shape around the welded region and the location of welded constrains. The results provide a guideline for an accurate finite element modeling of the spot-welded region in the crash analysis of vehicles.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2008.04a
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• pp.490-494
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• 2008

U-Channel Bridge is effective bridge type, because its edge beam performs role of barrier and enables to reduce additional dead loads. Although it is effective to reduce additional dead loads, there is possibility of bridge collapse under impact load due to car crash. Also, edge beam must have ability to induce safe driving and prevent falling accidents. Therefore, it requires behavior analysis and property investigation through the vehicle impact crashing edge beam. This study presents method of structural analysis of U-channel bridge and investigates design specifications for the effect of the edge beam under the vehicle impact. Also, it carries out stability investigation of behavior of edge beam and slab, based on Korean Highway Bridge Design Specifications and AASHTO LRFD Bridge Design Specification.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.241-244
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• 2008

Automotive companies have conducted a study for light weigh body and crash safety. But It is difficult to adapt a mass production because of formability with high strength steel in the conventional stamping process. Recently, Automotive maker in the Europe, USA, Japan has applied a hot stamping with boron steel in the body structure. Hot stamping technology spread fast in various body parts of automobile. Bumper beam has been applied in the foreign automotive company so much nowadays. In this study, We will optimize crash performance of bumper beam using hot stamping through comparison with conventional bumper beam.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.326-330
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• 2007

Bumper back beam is one of the essential structural components of front-end module. It should be designed to withstand a minor bump in low-speed collision, 2.5 mph crash test for example. And weight reduction is always important problem in the design of almost all the parts in car for energy saving. So, the key issues in shape design of a bumper are weight reduction and the performance in 2.5mph crash test. In this study, a light weight and high performance bumper back beam model was developed using analytical approach based on mechanics and FE simulation together.

• Transactions of Materials Processing
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• v.20 no.8
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• pp.555-561
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• 2011

The energy absorbing characteristics of crash members in a car collision play an important role in controlling the amount of damage to the passenger compartment. Crash members filled with aluminum foam are expected to have reduced mass while maintaining or even improving the crashworthiness compared to the conventional hollow-beam types. Finite element simulations are carried out in the present work to assess the improvement of crashworthiness by the use of aluminum foam fillers. The numerical results agreed well with experimental measurements. Parametric studies are conducted to analyze the effect of impact velocity, weld strength, and initiator on the crash response.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.82-87
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• 2012

The purpose of this study is to produce a side impact beam with high tensile steel using a roll forming process. The door side impact beam plays an important roll in a car because it protects passengers from external crash. The roll forming process is a continuous bending process wherein a long metal sheet is bended as it continuously passes several rolls. The characteristic of this study is that an impact beam is produced by a continuous process using a ultra high strength steel without a hardening heat treatment. A model was determined by analysing plasticity of a cross section shape considering high strength. Design parameters of the impact beam was determined by crash-analysing the model. Workpiece products were manufactured by designing dies for roll forming and setting them up in a following process line. Results of a bending test and a FEM analysis was considered and reviewed.