Finite-Element Crash Test Simulation of New York Portable Concrete Barrier with I-Shaped Connector

Abstract

Use of finite-element simulations in designing and analyzing roadside hardware has increased significantly over the past decade. Due to considerable progress in computer technology in conjunction with nonlinear finite-element software, outcome of complex vehicle-roadside hardware collisions can be accurately predicted using simulation programs. In this paper, the finite-element simulation program LS-DYNA was used to analyze and improve the crash test behavior of New York Department of Transportation Portable Concrete Barrier (NYPCB). A full-scale crash test demonstrated that the current NYPCB design was unable to meet national standards. Inspections after the test revealed that the welding at metal connectors forming the joint between the barrier segments was not properly fabricated. A finite-element representation of the crash-tested barrier was developed with a special fillet weld with failure model and subjected to crash testing using the nonlinear finite-element code LS-DYNA. This baseline model simulation was intended to replicate the failed crash test and validate the fidelity of the finite-element models. Qualitative and quantitative comparisons show that the baseline model simulation was successful in replicating the failed crash test. Upon validation, an improved NYPCB model was developed by using proper welding details and subjected to full-scale impact simulation to determine whether this design would satisfy the crash testing requirements. Results of the simulation were encouraging. It was predicted that the barrier would successfully contain and redirect the impacting vehicle in a stable manner. Subsequent full-scale crash testing on the NYPCB with proper welding details passed the NCHRP Report 350 requirements and substantiated LS-DYNA predictions.