Week 11 Car Crash simulation

Objective:- This challenge aims to perform the parametric analysis of the Frontal car crash test using three different thickness of 0.3mm, 0.5mm, 0.7mm for the car body.

Geometry:

The Geometry consisits of two bodies 1) Wall, 2) Car Body.

After importing the model in Ansys mechanical, make the model symmetric so that we can get the results over all the body.

Go to 'Model>symmetry>symmetric region'.

Material: The material for car body is stainless steel Non-linear and for the wall,it is structural steel.

The properties of the materials are given below.

Stainless steel NL:

Structural steel:

In this analysis, no contact is used as we want to test the import on the car body due to a crash with rigid wall.

Meshing:-

Given the mesh for both car body and wall.

We have used some finer mesh in the area which is going to in contact with the wall. We have used face sizing at that particular location.

Boundary conditions and analysis settings:

We have fixed the car with fixed support and given the displacement of 500mm to the wall.

Fixed Support:

 

Displacement:

 

In Analysis settings End time = 0.001 sec.

Results:

Energy convergence:

1) Thickness of 0.3mm:

Total Deformation:

Directional Deformation:

Equivalent Stress:

2) Thickness of 0.5mm :

Total deformation:

Equivalent stress:

3) Thickness of 0.7mm:

Total deformation:

Equivalent stress:

Animation Link: 

https://drive.google.com/file/d/1cG7YxMr8Ul7cDLLvsxqkOKTO088xTevq/view?usp=sharing

Conclusion:

- The car crash simulation was set up and all test cases ran successfully.

- From the above results we can conclude that deformation is decreasing and stress is increasing to a small extend as an increase in the thickness of the car body.

- In case 3 as the thickness is 0.7mm the directional deformation and total deformation is less compared to the case 1 and case 2 but it is too small to consider for a design hence from the results obtained the 0.3mm thickness car body design is  safe for manufacturing.

Google drive link:-https://drive.google.com/file/d/1oYs7oxkeXRIXD-PAGiHQiTicLlVz3TjM/view?usp=sharing