This document proposes a summer project to analyze the influence of crash boxes on crashworthiness using Ansys Explicit STR. The project would involve designing different crash box geometries, implementing them in an explicit simulation environment, simulating frontal impacts, and analyzing the resulting stress variations with and without crash boxes. The goal is to select the crash box material and geometry that protects structural integrity up to a certain impact level. Future work could involve using LS-OPT to mathematically optimize the crash box geometry and material properties to improve performance.
This document proposes a summer project to analyze the influence of crash boxes on crashworthiness using Ansys Explicit STR. The project would involve designing different crash box geometries, implementing them in an explicit simulation environment, simulating frontal impacts, and analyzing the resulting stress variations with and without crash boxes. The goal is to select the crash box material and geometry that protects structural integrity up to a certain impact level. Future work could involve using LS-OPT to mathematically optimize the crash box geometry and material properties to improve performance.
Original Description:
Analysis of Crash Box Influence on Crashworthiness Using Ansys Explicit STR
This document proposes a summer project to analyze the influence of crash boxes on crashworthiness using Ansys Explicit STR. The project would involve designing different crash box geometries, implementing them in an explicit simulation environment, simulating frontal impacts, and analyzing the resulting stress variations with and without crash boxes. The goal is to select the crash box material and geometry that protects structural integrity up to a certain impact level. Future work could involve using LS-OPT to mathematically optimize the crash box geometry and material properties to improve performance.
This document proposes a summer project to analyze the influence of crash boxes on crashworthiness using Ansys Explicit STR. The project would involve designing different crash box geometries, implementing them in an explicit simulation environment, simulating frontal impacts, and analyzing the resulting stress variations with and without crash boxes. The goal is to select the crash box material and geometry that protects structural integrity up to a certain impact level. Future work could involve using LS-OPT to mathematically optimize the crash box geometry and material properties to improve performance.
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Summer Project Title Submission
Analysis of Crash Box Influence on Crashworthiness
Using Ansys Explicit STR Abhishek Verma, Department of Industrial Design, NIT Rourkela,
Introduction Crash absorbing materials are being used in industry to reduce impact of collision on worthy structure often referred as crashworthy, as they could sustain crash up to a certain limit without causing any damage to the integrity of structure as a whole. In automobile industry crashworthy structure absorbs impact energy in a controlled manner. The sudden impact of collision cause huge amount of impulse and deceleration. Energy absorption by using metallic absorber is achieved by progressive buckling using folding deformation using initiators such as ribs, holes, folds, cuts, different shapes of sections, elements with variable thickness and constant increase of sections and of inertia moments. The key feature of these crash boxes is that deformation that rate of energy dissipation is concentrated over relatively narrow zones and other part of structure undergoes rigid body motion.
Justification for Project Title
Crash worthiness of an automotive is not an additional feature in a product anymore, according to the guidelines issued by government it is a compulsory norm which must be fulfilled that a vehicle should sustain impact up to certain level before catastrophic failure. Now a days customer also prefer safety over price that is why we see new safety features associated with a car like safety air bags. A crash worthy car from manufacturers point of view should be economically and technically feasible to manufacture. Use of crash box in a car front seems to be economical as there is no significant manufacturing process is required for production. It protects the structural integrity of vehicle up to a certain impact.
Problem Statement Selection of material and geometry of crash box and implementing it on frame rail attached to a rigid bumper. Using Ansys Explicit STR and comparing stress variation of different models with and without crash box.
Fig.1: three different configurations (M1 without crash box, M2 and M3 with different combinations.) [1]
Fig 2: Comparison of stress variations of geometric models during the impact
simulation [1]
Future Work: (Design of crash box using LS-OPT and Explicit
simulation of crash box on LS DYNA) It is useful to utilize mathematical optimization by altering the geometry and the material and structural properties of the bumper- beam and crash box to improve the low/high speed performance. LS-OPT is a tool which is being used for geometrical modeling of crash box. LS-OPT is associated with LS DYNA a software which is used to solve explicit problems and simulations. LS OPT uses artificial neural control method to predict optimum design of various models. Deigning of crash box from scratch will require huge computing ability and computational time in weeks or may be months and keeping in mind resources available in our department it is impossible to consider it for summer project.
Project Timeline starting from May 1st 2016
Time (weeks) Work Literature review Design of crash box Design of Explicit Environmen t Simulation
Analysis of result
Report Writing
References [1] Mihail Daniel Iozsa, Dan Alexandru Micu, Gheorghe Fratila, Florincristian Antonache, Influence of Crash Box on Automotive Crashworthiness, Recent Advances in Civil Engineering and Mechanics, ISBN: 978-960-474-403-9; [2] Redhe, M., Nilsson, L., Bergman, F., Stander, N., Shape Optimization of Vehicle Crash-box using LS-OPT, 5th European LS-DYNA Users Conference, Birmingham, 2005; [3] 'Crashworthiness Investigation and Optimization of Empty and Foam Filled Composite Crash Box', Hamidreza Zarei, Aeronautical University, Tehran , Matthias Kroeger, University of Technology ,Iran; [4] Micu, D.A., Straface, D., Farkas, L., Erdelyi, H., Iozsa, M.D., Mundo, D., Donders, S., A cosimulation approach for crash analysis, UPB Scientific Bulletin, Series D: Mechanical Engineering, 76 (2), 2014, pp. 189-198; [5] Srbu, A.D.M., Research on improving crashworthiness of the frontal part of the automotive structure, PhD Thesis, Politechnica University of Bucharest, Romania, 2012; [6] Hamidreza Zarei, Matthias Kroger, Institute of Dynamics and Vibrations, University of Hannover, Germany, Optimum honeycomb filled crash absorber design, Materials and Design 29 (2008) 193204; [7] Hamidreza Zarei, Matthias Kroger, Henrik Albertsen, Institute of Dynamics and Vibrations, Germany, An experimental and numerical crashworthiness investigation of thermoplastic composite crash boxes, Composite Structures 85 (2008) 245257; [8] H R Zarei & M Krger, Crashworthiness optimization of empty and filled aluminum crash boxes, International Journal of Crashworthiness; [9] Gangadhar Biradar, Anjan Babu V.A, Automotive Crash Box Performance Analysis and Simulation during Frontal Rigid Barrier Crash, International Journal of Science and Research (IJSR), [10] Shokri EL Houssini, Daan Engineering, s.n.c , Front Bumper Crash Worthiness Optimization, 9th International LS-DYNA Users Conference
