Side Door Beam Research Articles

Numerical investigation of crash behavior of vehicle side door beams under high-speed pole side impacts

In side vehicle accidents, there is a very short distance between the impactor and the passenger. In such accidents, car manufacturers place impact energy absorber beams inside the door so that the passengers do not suffer from loss of life or major damage. In this study, the crashworthiness performances of impact energy absorber beams were investigated. Comparisons were made by changing the beams’ angles, materials, thickness, and cross-sections. Among the materials used (Aluminum 6061-T6 and A36 steel), Aluminum 6061T6 material stood out with its high Specific Energy Absorption (SEA) value, low reaction force, and low permanent deformation performance. The best Velocity Absorption Time (VAT) value was obtained in the combination where the angle between the two beams defined by A36 steel was 25°. It has been stated that the hexagonal cross-section door beam used is superior to the circular beam and is open to improvement.

A geometrical parametric study of side door reinforced beams under lateral impact load

In this work, crash characteristics of side door reinforced beams under low speed impact were investigated. The side door panels of three different cross-sections, namely, circular, U and W shapes were considered. The advanced high strength (AHS) steel grade 1000 was used and both quasi-static and dynamic tensile tests were carried out for obtaining the rate-dependent flow stress behaviour. The geometries of all panels were modified with a specified design space constraint. FE simulations of profile variants under lateral impact load were carried out and resulting peak forces and maximum intrusions were afterwards determined. The most effective geometrical parameters for enhancing impact resistance of each reinforced beam were identified. The Wshape panel exhibited the greatest compromise of increasing crushing force efficiency, potential of weight reduction and minimizing structural damage. Finally, side door beams with combined best configurations were proposed and their crashworthiness including normalized specific energy absorptions were compared.

Effects of vehicle safety design on road traffic deaths, injuries, and public health burden in the Latin American region: a modelling study

The Sustainable Development Goals (SDGs), which aim to halve global traffic deaths by 2020, will not be met by most low-income and middle-income countries (LMICs). In Latin America and the Caribbean (LAC) region, traffic deaths have remained stable at a high-level despite strong progress in other health domains. We evaluated the effects of road safety interventions in LAC and estimated the benefits that vehicle design improvements would have in this region. In our study done in October, 2018, we used a counterfactual analysis to assess the reduction in deaths and disability-adjusted life years (DALYs) lost if eight proven vehicle safety technologies were made more widely available in LAC countries. We estimated: (1) country-level incidence of traffic injuries, (2) the effectiveness of technologies through a systematic literature review, (3) the prevalence of car safety technologies, and (4) the lives saved and DALYs averted if all cars had these technologies. We characterised uncertainty in estimates by reporting the sensitivity of the results to alternative modelling assumptions. Increasing availability of electronic stability control, which includes antilock-brake systems, would have the largest benefits in the LAC region, estimated at 19·4% (sensitivity analysis range 8·6-31·1) fewer deaths and 17·0% (5·7-29·2) fewer DALYs. Increasing use of seatbelts would reduce deaths by 12·1% (9·1-15·5) and DALYs by 12·6% (9·4-16·3). Optimisation for side-impacts would result in 6·3% (3·1-6·5) fewer deaths, and improvements to vehicle front-end design would result in 6·0% (2·2-10·4) fewer deaths. The overall effect of improved vehicle design in the region would be 28·1% (12·8-39·2) fewer deaths, and 29·1% (13·5-39·8) fewer DALYs. Other safety technologies modelled, including airbag (front and side), side door beam, and side structure and padding, have smaller benefits. Regulating and encouraging the use of proven vehicle safety technologies in LMICs would have large gains and needs to be prioritised in the SDG agenda for 2030. Inter-American Development Bank.

Poprawa sztywności belki wzmocnienia tylnych drzwi samochodu osobowego

To protect passengers against consequences of side crash side door beams are assembled to doors of passenger cars. Their stiffness is examined during stand tests. The FE model to simulate such a test is described. After verification the model has been applied to improve of rear door side beam stiffness.

자동차 도어 경량화를 위한 판재형 사이드 임팩트 빔 개발 프로세스

This paper presents the development process of automotive side door impact beam for passenger cars. Weight reduction while maintaining functional requirements is one of the major goals in the automotive industry. In this study, thin-walled side door beam using quenchable boron steel was designed to reduce the weight of conventional side door tubular one. In order to estimate design for the proposed side door beams, the static side impact protection tests(FMVSS 214) were conducted using the finite element method. Based on the simulation results, geometry modification of the side door beam has been performed via creating new reinforcing ribs. Furthermore, the manufactured frontal impact beam was mounted on the real side door of a passenger car, and then static impact protection test carried out. It is concluded that the presented test results can provide significant contribution to the stiffness of side door impact beams and light-weighting door research.

Simulation and experimental verification of flexible roll forming of steel sheets

Roll forming is a sheet metal forming process that has been used for decades. Usually roll-formed sections have a constant cross section. Flexible roll forming is a brand new forming process that produces parts with variable cross sections, in which the rollers translate back and forth in a direction that is perpendicular to the sheet feeding direction. Theoretical analysis gives an explanation of the plane strain state, compressive stresses, tensile stresses, and shear stresses in flexible roll forming. In order to analyze the mechanics and the deformation characteristics of flexible roll forming, the finite element method (FEM) model of a 17-step flexible roll forming process is established. The yield criterion used in the FEM simulation is Hill 48, and the parameters of which are solved with the yield stresses under different loading conditions and are firstly verified with a plane strain tensile test. The complicated roller paths are realized with data extracted from the computer-aided design (CAD) files with VC++ programs developed by the authors. We developed the first flexible roll forming prototype machine in China, with which the roll forming experiment of a side door beam is performed. Final shapes of the experimental and numerical results are compared. It is shown that the numerical results based on Hill 48 yield criterion that is solved with yield stresses agree well with the experimental results, which indicates that the simulation model can well reflect the real forming process. Detailed analysis of the distribution and history of plastic strain, longitudinal strain, shear strain, and thickness of both the constant cross section and the variable cross section is performed, which is of great help to understand this forming process.

Crashworthiness Design of Vehicle Side Door Beam Based on Elliptical Geometry Modification Using Multi-Objective Optimization

Side Door Beam (SDB) is one of the crucial parts of today’s vehicles in order to meet the passenger safety. Through an explicit finite element analysis (FEA), material selection for the SDB under impact is evaluated by using three different sheets of material to achieve the maximum possible specific energy absorption (SEA). To find the lowest peak load, the carefully chosen SDB is investigated based on its orientation angle toward the rigid wall impactor. The elliptical cross section of the selected SDB is taken into account by considering two variables of geometrical parameters; thickness and minor to major diameter ratios. Accordingly, Multi-objective optimization of the SDB is performed using response surface method (RSM) to reach the mentioned objectives and to determine the optimal sectional configuration of the SDB

Crashworthiness design of vehicle side door beams under low-speed pole side impacts

In low speed collisions, insurance cost is a factor which is taken into account as a design criterion to reduce structure damage and fixing cost. In this study, it is focused on the applied permanent damages of vehicle frontal door caused by pole impacts. In the side impact, the side door beam is responsible to absorb the most possible kinetic energy. Two significant parameters including material and geometry of a side door beam are discussed here to reduce permanent damage of the door. To study the effect of material as the first phase, six different sheets of material have been concerned to investigate the rigidity of the structure. For the second phase, geometry modification of the side door beam has been performed via creating new CAD-reinforcing ribs. Consequently, the strength in elasto-plastic mode, maximum deflection and plastic strain of the equipped system representing the permanent damage is obtained in order to achieve lower losses.

Optimization of Circular Side Door Beam for Crashworthiness Analysis

Structural optimization related to crashworthiness and energy absorption capability is particularly importance to the automotive industry. The optimization involves highly nonlinear computational analysis and design with many material and structure parameters. This paper presents a crashworthiness design of the circular side door beam which attach to the side door structures. The response surface method (RSM) is utilized to formulate the complex crashworthiness design problem in the case of optimization. In this study, side door beam will be optimized. The beams in circular shape were studied and compared. The focus is on finding an optimum cross-section shape of the beam in order to improve the energy absorption character. An optimization problem is formulated to find the maximum energy absorbed with the maximum peak load as a constraint, the shape of the beam cross section and the thickness as variable. The structure optimum design and simulation analysis of automobile side-door beam was carried out by using Finite Element (FE) method.

Optimization of an automotive side door beam, considering static requirement

Door stiffness is one of the important factors in side impact. A side door beam is installed in the door to protect occupants from side impact. Generally, side impact performance has been calculated with the assembled door unit or the body-in-white (BIW) system. Thus, the effects of a side door beam should be investigated after a BIW system is designed. This research concentrates on the side door beam, which will be optimized. The cross-section of a side door beam is defined to have an elliptic shape. An optimization problem is formulated to find the design maximizing the crush stiffness within the specified weight. Design variables are the radii and the thickness of the side door beam with the elliptic section. Analysis of the side impact is carried out by the non-linear finite element method. The optimization problem is solved by two methods. One is the experimental design scheme using an orthogonal array. The other is optimization using the response surface method (RSM). Both methods have obtained better designs than the current one.