Experimental and Analytical Study of the Crashworthiness for the 2005 Ford GT Aluminum Spaceframe

2005 ◽  
Author(s):  
Ari G. Caliskan ◽  
Richard A. Jeryan ◽  
Huibert Mees ◽  
Simon Iregbu
Keyword(s):  
Automobile Industry ◽  
Light Weight ◽  
Rigid Barrier ◽  
Strain Behavior ◽  
Full Vehicle ◽  
Front End ◽  
Aluminum Castings ◽  
Vehicle Impact ◽  
Aluminum Profiles ◽  
6Xxx Series

The use of aluminum structures in the automobile industry have been increasing in the past decade due partly to the demand for light-weight vehicles, and in some instances, lower investment costs. In the case of the 2005 Ford GT, an aluminum spaceframe architecture was chosen. The spaceframe structure consists mainly of extruded 6xxx series aluminum profiles with aluminum castings acting as suspension attachment points. The aluminum castings, located at both the front and rear of the vehicle, also act as nodes to which a number of extrusions are welded. This architecture resulted in a very stiff, yet light-weight vehicle. In addition to stiffness and weight advantages, the use of both aluminum members and the spaceframe construction proved to have good crashworthiness properties for all impact modes. In this paper, the crash performance of the front end of the vehicle consisting of an extruded bumper and double-cell rail system is shown. Once the components were manufactured, specimen level tests were conducted to measure the stress-strain behavior of the extruded material. This information, along with the geometric data of the bumper and rails, was used to create models of the front-end of the vehicle. A series of analyses were conducted using a rigid barrier impact to determine crush loads as well as mode of collapse. Concurrently, the components were assembled and tested using a sled impact facility at speeds comparable to full vehicle impact speeds. The results of the component tests and the analyses showed that the models predicted both the crush loads as well as the crush modes accurately. This validation exercise proved to be key in creating accurate full vehicle models for all the crash modes that are required for certification of the vehicle. As such, development time as well as the number of full vehicle tests was reduced.

Light-Weight Tire Concept

1996 ◽  
Vol 24 (2) ◽  
pp. 119-131
Author(s):  
F. Lux ◽  
H. Stumpf
Keyword(s):  
Fuel Consumption ◽  
Automobile Industry ◽  
Rolling Resistance ◽  
Performance Standards ◽  
Light Weight ◽  
Production Methods ◽  
Lower Fuel Consumption ◽  
Material Resources ◽  
The Past ◽  
Tire Production

Abstract Current demands by the consumer, the automobile industry, and the environment have determined the basis of this investigation. In the past, the requirements—ever faster, ever sportier—were accepted as decisive parameters for the development of our study. In the future, rational and safety-related tire characteristics as well as environmental consciousness will increase, whereas purely performance-related parameters will diminish in their importance. Through our light-weight tire project, we have paved the way for future tire generations. The first priority is the minimal use of material resources; this means a reduction of materials and energy in tire production by using advanced design and production methods without sacrificing performance standards. This benefits the consumer—the final judge of all of our activities—by considerably reducing the rolling resistance, leading to lower fuel consumption. Further design targets include the improvement of rolling behavior and increased comfort by reducing tire weight, and therefore a reduction in unsprung masses on the vehicle.

Injury biomechanics-based nondeterministic optimization of front-end structures for safety in pedestrian–vehicle impact

2021 ◽  
Vol 167 ◽  
pp. 108087
Author(s):  
Fei Lei ◽  
Xiaojiang Lv ◽  
Jianguang Fang ◽  
Tong Pang ◽  
Qing Li ◽  
...  
Keyword(s):  
Injury Biomechanics ◽  
Front End ◽  
Vehicle Impact

Effects of vehicle front-end safety countermeasures on pedestrian head injury risk during ground impact

2019 ◽  
Vol 233 (14) ◽  
pp. 3588-3599 ◽  
Author(s):  
Liangliang Shi ◽  
Yong Han ◽  
Hongwu Huang ◽  
Wei He ◽  
Fang Wang ◽  
...  
Keyword(s):  
Injury Risk ◽  
Rotation Angle ◽  
Head Injuries ◽  
Leading Edge ◽  
Vehicle Safety ◽  
Secondary Impact ◽  
Front End ◽  
Vehicle Impact ◽  
Safety Countermeasures ◽  
Primary Impact

Pedestrian safety countermeasures such as pop-up bonnets and exterior pedestrian airbags have been shown to decrease the pedestrian injury risk caused by vehicle impacts (primary impact). However, it is still unknown whether these devices could prevent or mitigate pedestrian injuries resulting from ground impacts (secondary impact). In order to understand how the vehicle safety countermeasures prevent pedestrian head injuries caused by primary and secondary impacts, a total of 252 vehicle-to-pedestrian impact simulations were conducted using the MADYMO code. The simulations accounted for three types of vehicle configurations (a baseline vehicle and vehicles with the two aforementioned vehicle safety countermeasures) along with five front-end structural parameters at three vehicle impact velocities (30, 40, and 50 km/h). The simulation results show that the bonnet leading edge height was the most sensitive parameter affecting the head-to-vehicle impact location and that caused different head injuries resulting from the local stiffness in the location impacted. Moreover, the bonnet leading edge height was the leading governing factor on the pedestrian rotation angle in the secondary impact. The vehicle equipped with a pop-up bonnet and an external airbag could cause a larger pedestrian rotation angle at 30 km/h than that in the other two vehicle types, but conversely could cause a smaller pedestrian rotation angle at 40 and 50 km/h. Also, the vehicle equipped with pop-up bonnet and external airbag systems could lead a higher pedestrian flight altitude than that of the baseline type. A vehicle equipped with a pop-up bonnet and external airbag systems provide improved protection for the pedestrian’s head in the primary impact, but may not prevent the injury risk and/or even cause more severe injuries in secondary impacts.

Improvements in Vehicle Stiffness by Adding Internal Reinforcements

2017 ◽  
Vol 9 (2) ◽  
Author(s):  
R. Mohan ◽  
V. Hariram ◽  
M. Subramanian ◽  
S. Padmanabhan
Keyword(s):  
Topology Optimization ◽  
Automobile Industry ◽  
Climatic Conditions ◽  
Light Weight ◽  
Low Carbon ◽  
Load Path ◽  
Bending Performance ◽  
Conceptual Design Phase ◽  
Minimal Mass ◽  
Torsion Stiffness

The world’s climatic conditions rises and there is a demand for environment friendly vehicle designs. The automobile industry strives hard to ensure low carbon emissions. This refers to the mass reduction and fuel consumption. This paper investigates to achieve the overall Body-in-white (BIW) bending and torsion stiffness performance using Topology optimization and light weight internal reinforcements. The potential opportunity of achieving light weight structure using the efficient way of defining the internal reinforcements has been investigated. BIW at the conceptual design phase has been considered for the research. Topology optimization was performed considering the roof rail and the rocker as the design space with an approach of achieving the improved torsion and bending stiffness performance. The optimized bulk head design locations have improved the BIW stiffness performance with minimal mass increase in the BIW. This method can be widely used at various stages of the BIW design to identify the weaker sections and then design the load path using internal reinforcements effectively. The optimized internal reinforcements has achieved higher torsion and bending performance with minimal mass addition.

Numerical Approach for the Evaluation of Seam Welding Criteria in Extrusion Processes

2012 ◽  
Vol 504-506 ◽  
pp. 517-522 ◽  
Author(s):  
Martin Schwane ◽  
Thomas Kloppenborg ◽  
Andreas Reeb ◽  
Nooman Ben Khalifa ◽  
Alexander Brosius ◽  
...  
Keyword(s):  
Automobile Industry ◽  
Numerical Approach ◽  
Extrusion Process ◽  
Experimental Investigations ◽  
Welding Quality ◽  
Seam Welding ◽  
Numerical Investigations ◽  
Welding Line ◽  
Aluminum Profiles ◽  
Longitudinal Seam

The accurate simulation and the optimization of extrusion processes can be a helpful technique to ensure producibility of complex aluminum profiles, for example for the automobile industry. Currently, the die designing is based on expert’s knowledge and cost-intensive prototyping. The paper deals with numerical investigations based on finite element simulations as well as experimental investigations of an industrial extrusion process. A newly developed method for longitudinal seam weld prediction is applied to analyze the position of the longitudinal welding line and the welding quality.

Flexible and Intelligent Gripping Technology for Machining and Handling of Spatially Curved Extruded Aluminum Profiles

2006 ◽  
Vol 10 ◽  
pp. 153-162 ◽  
Author(s):  
G. Lanza ◽  
Jürgen Fleischer ◽  
Daniel Ruch
Keyword(s):  
Extrusion Process ◽  
Frame Structures ◽  
Medium Size ◽  
Light Weight ◽  
Batch Production ◽  
New Approach ◽  
Process Chains ◽  
Clamping System ◽  
Aluminum Profiles ◽  
Flexible Machines

With a novel extrusion process which is investigated in the Collaborative Research Center Transregio 10 (SFB/TR10), it is possible to manufacture spatially curved aluminum profiles. This process is the base for an automated small and medium size batch production of light-weight frame structures. For the handling and machining of the spatially curved profiles, highly flexible machines and manufacturing equipment are needed. Today’s automated process chains do not reach a sufficient flexibility. This article introduces a new approach to handle and machine spatially curved profiles using a flexible gripping and clamping system. Firstly, the requirements concerning the process comprehensive gripping technology, which have to be fulfilled for a flexible small and medium batch production of light-weight frame structures, are specified. Subsequently, the function and design of a flexible gripping and clamping system are described. Furthermore, metrological processes to maintain a once reached condition of order during the entire process chain are depicted.

Specifying Steel Properties and Incorporating Forming Effects in Full Vehicle Impact Simulation

2002 ◽  
Author(s):  
D. Zeng ◽  
S. D. Liu ◽  
V. Makam ◽  
S. Shetty ◽  
L. Zhang ◽  
...  
Keyword(s):  
Impact Simulation ◽  
Full Vehicle ◽  
Vehicle Impact ◽  
Steel Properties

Design and ANSYS analysis of Components of Wheel Assembly of SAE Car

2018 ◽  
Vol 8 (02) ◽  
Author(s):  
Sameer Santosh Mahadik
Keyword(s):  
Automobile Industry ◽  
Dynamic Condition ◽  
Light Weight ◽  
Vehicle Performance ◽  
Performance Requirement ◽  
Ansys Analysis ◽  
Track Condition

In automobile industry it is essential to produce the light weight assembly in order to increase the vehicle performance. Also, lots of forces during braking, acceleration and bump conditions are also applied directly during dynamic condition. So, this paper deals with calculation of various loads and their simulation. The FEA result indicates that the upright assembly is able to perform safely in real track condition as per performance requirement.

Research of Automobile Tire Vertical Stiffness Optimization Method on the Basis of ADAMS/Car

2013 ◽  
Vol 561 ◽  
pp. 527-532
Author(s):  
Ze Peng Wang ◽  
Zhen Yu ◽  
Ke Li
Keyword(s):  
Ride Comfort ◽  
Optimization Method ◽  
Vehicle Model ◽  
Vertical Stiffness ◽  
Automobile Tire ◽  
Full Vehicle ◽  
Stiffness Optimization ◽  
Vehicle Impact ◽  
Simulation Results ◽  
The Impact

Because Tire not only impact on the handling stability of vehicle but also impact on the ride comfort, it is more practical significant that tire vertical stiffness parameters on handling stability and ride of vehicle impact is considered synthetically than considering handling stability and ride singly. In this paper, full vehicle model was built on the basis of ADAMS/Car. The vertical stiffness of tire was only changed and other parameters remain unchanged, then full vehicle analysis was carried out to get the simulation curves. The impact of the vertical stiffness of tires on the handling and stability and ride comfort was obtained from the curves of simulation. The tires of optimized vertical stiffness can be obtained from the comparison of simulation results. Analytical results can be conductive to designing and producing the tire.

scholarly journals Microstructure And Mechanical Properties Of Synthesized Aluminium Composite Using Stir Casting Process

2019 ◽  
Vol 4 (2) ◽  
Author(s):  
Anubhav Coyal ◽  
N. Yuvraj ◽  
Ravi Butola ◽  
KapilDev Pandey ◽  
Tusharjeet Singh Kalra
Keyword(s):  
Automobile Industry ◽  
High Strength ◽  
Casting Process ◽  
Stir Casting ◽  
Light Weight ◽  
Aluminium Composite ◽  
Sem Images ◽  
Specific Strength ◽  
Space Industry ◽  
Before And After

Aluminium is one of the most common metals in the world and its use is increasing day by day in many industries mostly in space industry and automobile industry because of its light weight and high strength capabilities. Aluminium-based alloys have great potential for cost saving application due to their light weight combine with high specific strength and corrosion resistance, as well as good castability. This paper mainly emphasis with the fabrication of Aluminium composites with SiC particles and jute ash particles. Hardness and tensile properties of the prepared Aluminium composite were determined before and after addition of SiC and Jute Ash particulates to find the extent in improvement of properties. SEM images have shown the grain boundaries formation. Results shows that the tensile strength is maximum in case of composite with SiC with value of 123MPA when compared to unreinforced 6061Al matrix with strength of 64MPa.

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