FRONTAL CRASH
Frontal Crash Test -
THIS IS THE FULL CAR MODEL WHICH CAN BE DOWNLOADED FROM ALTAIR WEBSITE BUT DUE TO NODE LIMIT FOR THE A PORTION OF THE BIW IS ONLY TAKEN INTO CONSIDERATION
THIS IS THE MODEL WHICH WILL BE SOLVED IN FRONTAL CRASH ASSIGNMENT -
RESULTS EXPECTED -
1. SECTIONAL FORCES CURVES AT A-PILLAR, SHOTGUN, RAILS, BUMPER-MOUNT, DOOR HINGE BEAM
2. DASHBOARD WALL INTRUSIONS AT BRAKE PEDAL AREA
UNIT SYSTEM FOLLOWED -
kg,mm,ms,KN
MATERIAL SELECTION -
Its a sheet metal shell inside which foam is filled
For other sheet metal components -
This process is one for all the components
PROPERTY SELECTION -
PROP SHELL CARD
P14 - SOLID CARD
INTERFACE CARDS -
I have tried to use two car types i.e interface Type-7 and Type-11
Type-7 Card -
It\'s a node to surface contact (Self Contact is Turned On) -
I stiff - 2
I Gap - 3 (Variable Gap+Scale correction Factor+% Mesh Size)
I Del - 2
F_Scale Gap - 0.8
St_min - 0.1
Friction - 0.2
Gap_min - 0.5
I_Form - 2 Stiffness
PENETRATION CHECK -
Initial Velocity -
Rigid Wall -
Def - Infinite Plane Type
Slide - 2: slide with Friction
D_search - 800 mm
Friction - 0.2
Output Request -
1. Sectional Forces - Rails, shotgun, door hinge, Bumper Mount, A-Pillar
2. Acceleration - At accelerometer at the base of B-Pillar
3. Rigid Wall Forces
4. Interface Forces
5. Velocity of Accelerator master node
6. The intrusion of the brake pedal and accelerator pedal - By creating a local system and measuring distance relative to it
ACCELEROMETER
SECTIONS AT DIFFERENT LOCATIONS
INTRUSION AT NODE 1
INTRUSION AT NODE 2
Control Cards -
Engine DT Brick -
Engine DT INTER -
ENGINE DT NODA -
ENGINE ANIM_DT -
UNIT SYSTEM - CAN BE SEEN IN BEGIN CARD
ENERGY ERROR AND MASS ERROR -
No Sudden jumps in time step and energy error or mass error
Mass Error - (0.1346%)
Energy Error - (-2.1%)
Energy Curves -
Nodal Velocity of accelerometer -
Interface forces -
Rigid Wall Forces -
A-Pillar Sectional Forces RH-
Shotgun Sectional Forces -
Rail Sectional Forces-
Bumper To ShotGun Mount Sectional Forces-
Door Hinge Beam Sectional Forces -
Acceleration -
CRASH SIMULATION TYPE-7 RESULTS -
VON-MISES -
PLASTIC STRAIN -
NOW I HAVE TRIED ADDING TYPE-11 CONTACT WITH TYPE-7 JUST TO CHECK WHAT WILL BE THE VARIATION IN THE RESULT -
DEFORMATION RESULT -
VON-MISES -
PLASTIC STRAIN -
ENERGY-CURVES -
RIGID WALL FORCES -
INTERFACE FORCES TYPE 7 -
INTERFACE FORCES 11 -
A-PILLAR SECTION FORCES -
SHOTGUN SECTIONAL FORCES -
RAIL SECTIONAL FORCES -
DOOR HINGE BEAM SECTIONAL FORCES -
BUMPER MOUNT SECTIONAL FORCES -
VELOCITY CURVE OF MASTER NODE OF ACCELERATION SENSOR -
ACCELERATION SENSOR DATA -
ACCELERATOR PEDAL INTRUSION -
BRAKE PEDAL INTRUSION -
MASS AND ENERGY ERROR DATA -
MASS ERROR - (0.1349%)
ENERGY ERROR - (-2.2%)
COMPARISON TABLE OF HOW MAX. VALUE OF DIFFERENT FILED IS CHANGING WITH VARIATION IN CONTACT -
ALL THE FORCES ARE IN KN AS PER THE UNIT SYSTEM
|
DATA |
TYPE 7 ONLY |
TYPE 11 AND 7 BOTH |
|
DEFORMATION |
1.284E+03 |
1.294E+03 |
|
VON MISES STRESS |
3.97E-01 |
3.961E-01 |
|
PLASTIC STRAIN |
1.106 |
1.096 |
|
INTERFACE FORCES TYPE 7 |
100 |
102 |
|
RIGID WALL FORCES |
100 |
120 |
|
A-PILLAR SECTIONAL FORCES |
3 |
3.25 |
|
SHOTGUN SECTIONAL FORCES |
8.2 |
8.1 |
|
RAIL SECTIONAL FORCES |
40 |
42 |
|
BUMPER MOUNT SECTIONAL FORCES |
10.3 |
9.4 |
|
DOOR HINGE BEAM SECTIONAL FORCES |
9.8 |
9.8 |
|
ACCELERATION |
20.75 |
20.75 |
CONCLUSION -
RESULTS ARE SHOWN HERE IN THIS TABLE PLEASE CHECK INTRUSIONS CURVES ARE ALSO THERE, SIMULATION RESULT IS CORRECT BECAUSE THERE IS NO SUDDEN JUMP IN TIME STEP ENERGY ERROR AND MASS ERROR, ALL OTHER ENERGY CURVES ARE ALSO AS EXPECTED.
1. AS EXPECTED RAILS OF THE CAR IS TAKING THE MAX FORCE IN THE WHOLE BIW WHICH WILL BE THE MOST IMPORTANT ZONE IN THE STRUCTURE
2. SHOTGUN ARE DESIGNED TO FOLD DOWN WHILE CRASH IS HAPPENING WHICH CAN BE EXPECTED BECAUSE AS IN THE DESIGN SERIES OF NOTCHES ARE GIVEN SO AS SHOTGUN HITS THE WALL IT START FOLDING DOWN AS GUIDED BY THE SERIES OF NOTCHES
3. RAILS ARE ALSO DESIGNED IN SUCH A MANNER THAT IT ALSO CRUMPLE WHILE FOLDING DOWN SO AS GUIDE THE ENGINE DOWN WHICH IS PREVENT THE ENGINE TO PENETRATE FROM INTO THE DRIVER COMPARTMENT
4. FRONT BUMPER IS A SHEETMETAL PART WHICH HOLLW INSIDE AND IN THAT HOLLW PART FOAM MATERIAL IS COMPLETELY FILLED WHICH ABSORBING A LOT OF ENERGY, YOU CAN ALSO SEE IT BEFORE ITS SHAPE WAS AN ARC BUT IT FLATTENS OUT AFTER HITTING THE WALL .
ONE FAULT IN THIS SIMULATION WA SAS THE REAR PART OF THE STRUCTURE IS NOT PRESENT DUE TO WHICH TORSIONAL RIGIDITY IS LOST OF THE STRUCTURE IF A RIGID BODY WAS THERE TO HOLD THE STRUCTURE THEN IT MUST HAVE BEEN BETTER RESULT