Modeling of Modified Vehicle Crashworthiness using a Double Compound Pendulum

Vehicle crash modeling has been a challenge for researchers for several decades. Occupant injury prevention and prediction is a critical area within vehicle safety design. The modeling of material failure in structural members during a full frontal crash has been presented in this paper. This study presents a Lumped Parameter Model (LPM) with an elastic double compound pendulum replicating the impact kinematics. The model defined using Lagrangian formulation; presents a novel methodology to represent material fracture caused due to heat affected zones or welding in Ultra High Strength Steels (UHSS) in a non-linear crash event. The material fracture leads to rotation of the vehicle; presente…

Crash Response of a Repaired Vehicle - Influence of Welding UHSS Members

On the Effect of Various Heat Treatments on Microstructure of AISI 4130 Steel Used in Sour Service Pipes

Abstract Nowadays welding is the most common way to connect metal parts and structures. One of the challenges connected to welding it that heat output from the welding alters the microstructure of the metal creating the heat affected zone (HAZ) near the weld. In steel welds HAZ is often harder and more brittle than the base material due to formation of martensite. This might cause hydrogen induced cracking and speed up the fatigue of the weld. To mitigate the martensite formation in the HAZ different heat treatments, like preheat, interpass and PWHT are often applied. However, for 4130 steel, preheat and interpass temperatures are not expected to restrict martensite formation due to materia…

Experimental investigation of effect of printing direction and surface roughness on the mechanical properties of AlSi10Mg-alloy produced by selective laser melting

The additive manufacturing has initially gained popularity for production of non-loadbearing parts and components or in the fields where the material strength and ductility are less important such as modelling and rapid prototyping. But as the technology develops, availability of metal additive manufacturing naturally dictates the desire to use the produced components in load-bearing parts. This requires not-only a thorough documentation on the mechanical properties but also additional and independent research to learn the expected level of variation of the mechanical properties and what factors affect them. The presented paper investigates strength, ductility, hardness, and microstructure …

Mathematical models for assessment of vehicle crashworthiness: a review

This article reviews approaches to mathematical modeling of a vehicle crash. The growing focus on vehicle and occupant safety in car crashes has triggered the need to study vehicle crashworthiness in the initial stages of vehicle development. The major motivation for this work is to support vehicle crashworthiness design during the product development process.The article is divided into two parts; the first one overviews existing mathematical models used to solve engineering problems. The second part describes modeling strategies applied for replicating non-linear vehicle crash event and occupant kinematics in an occupant protection loadcase. We also highlight alternative modeling strategie…

Effect of welding and heat treatment on the properties of UHSS used in automotive industry

This paper deals with the undesired effects of the heat treatments on the mechanical properties of (UHSS) Ultra High Strength Steel used nowadays in automotive industry to improve crashworthiness performance of vehicles. The UHSS specimens were extracted from certain parts of the car body and subjected to different heat treatments. Four types of specimens were tested: untreated, welded with metal inert gas welding, heat treated at 800 °C, and heat treated at 1250 °C. All heat-treated specimens showed dramatically reduced values of strength. The results suggest that it is important to follow the official repair manuals avoiding unnecessary welding and improper heat treatments of UHSS. The ex…

A Novel Technique for Modeling Vehicle Crash using Lumped Parameter Models

This paper presents a novel technique for modeling a full frontal vehicle crash. The crash event is divided into two phases; the first until maximum crush and the second part when the vehicle starts pitching forward. This novel technique will help develop a three degrees of freedom (DOF) lumped parameter model (LPM) for crash and support in the vehicle development process. The paper also highlights the design process for reducing vehicle pitching in occupant protection load cases. The model has been validated against a finite element (FE) simulation of a full frontal crash of a Chevrolet Silverado developed by the National Highway Traffic Safety Administration (NHTSA), and the LPM shows goo…

On the Influence of Cross-Section Size on Measured Strength of SLM-Produced AlSi10Mg-Alloy

The freedom in choice of geometries in additive manufacturing (AM) favors the use of structures with large surface and small cross-section such as lattice structures and thin-walled hollow profiles. On the other hand, the practices of strength testing of metals require a certain bulk of the material to be printed to be able to produce a sample and test material properties. The size of the sample cross section might influence the strength and up to 30% decrease in strength for small struts was reported in the literature. Understanding the influence of the cross-section size on the strength of SLM-produced metal is crucial to be able to relate the strength determined through tensile testing a…

Vehicle crashworthiness performance in frontal impact: Mathematical model using elastic pendulum

Vehicle occupant injuries due to collisions cause many fatalities every year. Safe vehicle design plays a critical role in averting serious injuries to occupants and vulnerable road users in the event of a crash. In this paper we study a full frontal vehicle crash against a rigid barrier introducing a Lumped Parameter Model (LPM) inspired by the elastic pendulum motion. The model uses polar coordinates to simplify the problem and the governing equations have been defined using Lagrangian formulation. The Simulink model has been validated against Finite Element (FE) data demonstrating good correlation with pitching angle and maximum crush of the vehicle. These parameters are crucial for desi…

Effect of the Joint Strength on the Performance of Ordinary Moment-resisting Frames Under a Progressive Collapse Situation

Prediction of Vehicle Crashworthiness Parameters Using Piecewise Lumped Parameters and Finite Element Models

Estimating the vehicle crashworthiness parameters experimentally is expensive and time consuming. For these reasons different modelling approaches are utilized to predict the vehicle behaviour and reduce the need for full-scale crash testing. The earlier numerical methods used for vehicle crashworthiness analysis were based on the use of lumped parameters models (LPM), a combination of masses and nonlinear springs interconnected in various configurations. Nowadays, the explicit nonlinear finite element analysis (FEA) is probably the most widely recognized modelling technique. Although informative, finite element models (FEM) of vehicle crash are expensive both in terms of man-hours put into…