Crush Performance Comparison of FEE340 and DP600 Materials as Front Collision Rail in Automobiles

Abstract

    In this study, a frontal collision scenario (rigid wall test) is simulated in a computer environment using a half vehicle model for two different sheets of steel that are frequently used in automotive industry. The effects of materials, namely FEE340 steels in HSLA (High-Strength Low Allow) family and DP600 steels in DP (Dual Phase) family compared as front collision rails on crash performance of a vehicle. Front bumper cross member, crash box and collision rail in the model were designed using Siemens NX software. The pre-processing stage of collision elements before the dynamic analysis was carried out using Altair Hypermesh software. Abaqus software was used to create the dynamic analysis scenario of the model and to solve the analysis. The amount of energy absorption by each element, the total displacement, the level of the load transferred to the passenger compartment and the crush force efficiency (CFE) results were obtained from the simulations. According to the simulations results, although the CFE coefficients of FEE340 and DP600 materials are close, when the FEE340 material was used, the force transferred to the passenger compartment was 32% less, and the total displacement was 11% higher.

Keywords

• Crush analysis,finite element method,front collision rail,FEE340,DP600

OTOMOBİLLERDE ÖN ÇARPIŞMA KOLU MALZEMESİ OLARAK FEE340 VE DP600 MALZEMELERİN ÇARPIŞMA PERFORMANSLARININ KARŞILAŞTIRILMASI

Abstract

    Bu çalışmada, otomotiv endüstrisinde çok sık kullanılan iki farklı çelik malzeme için yarım araç modeli kullanılarak önden çarpışma senaryosu (rijit duvar testi) bilgisayar ortamında simule edilmiştir. Ön çarpışma kollarında kullanılan HSLA (High-Strength Low-Alloy) çelik ailesi grubundaki FEE340 ve DP (Dual Phase) çelik ailesi grubundaki DP600 malzemelerinin aracın çarpışma performansına olan etkileri karşılaştırılmıştır. Modeldeki ön tampon traversi, çarpışma kutusu ve çarpışma kolu Siemens NX yazılımı kullanılarak tasarlanmıştır. Tasarlanan çarpışma elemanlarının ön işleme prosesi, Altair Hypermesh yazılımı kullanılarak yapılmış ve dinamik analize hazır hale getirilmiştir. Modelin dinamik analiz senaryosunu oluşturmak ve analizin çözümü için Abaqus yazılımı kullanılmıştır. Simülasyonlardan, her bir eleman tarafından sönümlenen enerji miktarı, oluşan toplam deplasman, yolcu kabinine iletilen yük miktarı ve çarpışma kuvveti verimliliği (CFE) sonuçları elde edilmiştir. Bu veriler baz alınarak malzemelerin aracın çarpışma performansına etkileri değerlendirilmiş ve sonuç olarak FEE340 ve DP600 malzemelerinin CFE katsayıları yakın çıkmasına karşın FEE340 malzemesinin yolcu kabinine ilettiği kuvvetin %32 daha az, oluşturduğu deplasmanın %11 daha fazla olduğu görülmüştür.

Keywords

• çarpışma analizi,sonlu elemanlar,ön çarpışma kolu,FEE340,DP600

References

1. 1. Bois Paul Du, Chou Clifford C., Fileta Bahig B. & King Albert I. (2004). Vehicle Crashworthiness and Occupant Protection. American Iron and Steel Institute 2000 Town Center Southfield,Michigan 48075.
2. 2. Chiandussi, G., Avalle, M. (2002) Maximization of the crushing performance of a tubular device by shape optimisation, Computers and Structures, 80, 2425-2432.
3. 3. Deb, A., Gunti, R. S., Chou, C., & Dutta, U. (2015). Use of truncated finite element modeling for efficient design optimization of an automotive front end structure (No. 2015-01-0496). SAE Technical Paper.
4. 4. Edwards, M. J., Davies, H., Thompson, A., & Hobbs, A. (2003). Development of test procedures and performance criteria to improve compatibility in car frontal collisions. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 217(4), 233-245.
5. 5. Ensarioglu C., Gulcimen Cakan B., Reis M., Koluk H., Celik H., Uguz A., Cakir M. C. (2018). Reinforcement of a Thermoplastic Crash-Box with Aluminum Foam and Tie Beams. Academic Conference on Engineering, IT and Artificial Intelligence (AC-EITAI 2018), Prag.
6. 6. Eren, I., Gür, Y., & Aksoy, Z. (2009). Finite element analysis of collapse of front side rails with new types of crush initiators. International journal of automotive technology, 10(4), 451-457.
7. 7. Fekete, J. R., Stibich, A. M., & Shi, M. F. (2001). A comparison of the response of HSLA and dual phase sheet steel in dynamic crush (No. 2001-01-3101). SAE Technical Paper.
8. 8. George Mason University, (2016). 2010 Toyota Yaris Finite Element Model Validation Detail Mesh, Center for Collosion Safety and Analysis. (Doi: 10.13021/G8CC7G)

9. 9. Ghannam, M. Y., Niesluchowski, M., & Culkeen, P. M. (2002). Analysis of a Frontal Rail Structure in a Frontal Collision (No. 2002-01-0688). SAE Technical Paper.
10. 10. Gulcimen Cakan B., Reis M., Ensarioglu C., Koluk H., Yeni H., Uguz A., Cakir M. C. (2018). Termoplastik çarpışma kutularında alüminyum köpük takviyesinin çarpışma karakteristiğine etkisi. 18th International Conference on Machine Design and Production, 3-6 July, Eskişehir.
11. 11. Liu, X. T., Liu, C. H., Shi, S. L., Zhao, L. H., & Huang, H. (2010, February). The analysis of front rail crash on mini-bus chassis. In Computer and Automation Engineering (ICCAE), 2010 The 2nd International Conference on (Vol. 2, pp. 14-16). IEEE.
12. 12. Öztürk, İ., & Necmettin, Kaya (2008). Otomobil ön tampon çarpışma analizi ve optimizasyonu. Uludağ University Journal of The Faculty of Engineering, 13(1).
13. 13. Ramazani, A., Mukherjee, K., Abdurakhmanov, A., Prahl, U., Schleser, M., Reisgen, U., & Bleck, W. (2014). Micro–macro-characterisation and modelling of mechanical properties of gas metal arc welded (GMAW) DP600 steel. Materials Science and Engineering: A, 589, 1-14.
14. 14. Rao Lakshmana C., Narayanamurthy V., & Simha K. R. Y. (2016). Applied Impact Mechanics . Ane Books Pvt. Ltd. (ISBN : 978-11-1924-180-5).
15. 15. Tahan, F. J., Park, C. K., Morgan, R. M., Cui, C., Brar, B., Shanks, K., & Kan, C. D. (2013). The Effect of Reduced Mass on Frontal Crashworthiness. Proceedings of the IRCOBI Conference, 2013.