Car Crash simulation

Challenge: We have simulate a frontal impact car crash. A car with a certain speed hits at front part with object to undergoes front impact. This can also be define exactly opposite by an similar object hitting the stationary car\'s front part. Here, same approach we have used by assigned an oblect to hit a stationary car body at front.

Assigning structual steel material for wall itself, followed by Stainless Steel (Non-Linear) for Car body.

Providing thickness of 0.3mm which is also taken as a parameter for study. Also, since we assigned the body thickness as a parametric study performing a parametric study for a total of three study by assigning two more different thickness size of 0.5 & 0.6 mm

Symmetry Setting :

Assigned two symmetric regions for both wall and car body setup.

Mesh Setting :

Default mesh seem to create difficulty for solver since convergence is an issue. Hence, we increase mesh size by inserting a method of patch conforming, since its a metal surface we have assigned all triangle method and change the mesh smoothing quality from large to Medium. This generates a resonable mesh for pre-processing of simulation.

Generated Meshing :

Analysis Settings :

Now, we provide initial conditions for explicit dynamics module by assigning the end time of abount 0.001 sec and a maximum energy error of 0.1 respectfully. Rest settings are unchanged.

Boundary Conditions :

Fixed Supports

Boundary Conditions :

To simulate frontal impact crash we assigned a Displacement of 500mm to the back face of wall along Z-Axis.

Running the simulation and getting proper results

Simulation Result :

Equivalent Stress - Case 1

Equivalent Stress - Case 2

Equivalent Stress - Case 3

Total deformation - Case 1

Total deformation - Case 2

Total deformation - Case 3

Result :

Case 1- 0.3mm

Case 2 - 0.9mm

Case 3 - 1.8mm

Conclusion :

1. With increase in thickness values there is slightly decrease in total deformation.

2. With an increase in thickness the stress values also decreases significantly by small values.

3. The increase in thickness results decrease in ductile nature followed by increase in hardness of body.

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