Abstract
It is not uncommon to use profiles to act as energy absorption parts in vehicle safety systems. This work analyses an impact attenuator based on a simple design and discusses the use of a thermoplastic material. We present the design of the impact attenuator and a mechanical test for the prototype. We develop a simulation model using the finite element method and explicit dynamics, and we evaluate the most appropriate mesh size and integration for describing the test results. Finally, we consider the performance of different materials, metallic ones (steel AISI 4310, Aluminium 5083-O) and a thermoplastic foam (IMPAXX500™). This reflects the car industry’s interest in using new materials to make high-performance, low-mass energy absorbers. We show the strength of the models when it comes to providing reliable results for large deformations and strong non-linearities, and how they are highly correlated with respect to the test results both in value and behaviour.
Highlights
IntroductionA better understanding of the plastic behaviour of materials has made it possible to design structures that are more efficient at absorbing the energy released in an impact
There has been continual improvement in passive vehicle safety systems over recent decades.A better understanding of the plastic behaviour of materials has made it possible to design structures that are more efficient at absorbing the energy released in an impact
This work studied a proposed impact attenuator designed for a car’s energy absorption system. It included both the test of a prototype and finite element (FE) models solved with explicit dynamics
Summary
A better understanding of the plastic behaviour of materials has made it possible to design structures that are more efficient at absorbing the energy released in an impact. About 50% of the energy absorption effects are located along the front rail of the car, which makes it a critical component and a challenge for safety engineers (see, for instance, [1,2]). To better understand the energy absorption process, it is very important to study what is called “axial crushing” of the main metallic components. Some of the models presented served as a basis to further develop vehicle energy absorption (EA) systems [6,7] based on the use of profiled structures. The most common element was the so-called “crash box” which connected the front panel of the car with the front rail structure, and was mostly made of steel
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