Design assessment for reusability of an automotive safety beam

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Abstract

Vehicle crashworthiness is one of the key considerations in today's vehicle development program. The competitive environment requires carmakers to balance between achieving cost and time reduction while improving quality of their products. Quality here encompasses the safety performance in both preventing accidents from happening (active safety system) to protecting passengers from injuries (passive safety system). As reuse aims to sustain the function of old product or components for the second life, it will be necessary to preserve the materials. The other consideration is in terms of reusability of the beam as part of cost consideration especially in low impact scenario whereby deformation of the beam/structure may be minimal. In such cases, the damage or deformation has to be accessed to ascertain whether the beam can reused. This paper presents a study on the behavior of a door beam upon impact using Finite Element Analysis. The analyses include energy absorption characteristics, deformation and stress of the beam structure and also the effect of impactor on the crash characteristics of the door beam in terms of reusability. It was found that reusability is highly dependent on a number of factors such as the impactor kinetic energy (mass and speed) and materials characteristics. For metallic structure, reusability will be influenced by whether the material undergoes major permanent plastic deformation or behave within the elastic zone upon impact. Once the structure undergoes permanent plastic deformation reusability will not be possible. The results show that for impactor below 20kg, the beam of the car door will deform within the elastic region with the possibility of reusability. However, for load case 30kg and above, the beam undergoes permanent deformation which renders it useless after impact. Further investigation will be necessary to understand how different materials and geometry of the beam can improve the energy absorption characteristics and reduce damage of the car door assembly to enable reusability at the end of its life.

Original languageEnglish
Pages (from-to)167-175
Number of pages9
JournalAustralian Journal of Basic and Applied Sciences
Volume5
Issue number11
Publication statusPublished - Nov 2011

Fingerprint

Reusability
Energy absorption
Plastic deformation
Railroad cars
Active safety systems
Crashworthiness
Security systems
Kinetic energy
Costs
Accidents
Finite element method
Geometry

Keywords

  • Assembly
  • Automotive component reuse
  • Durability and materials
  • Impact

ASJC Scopus subject areas

  • General

Cite this

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title = "Design assessment for reusability of an automotive safety beam",
abstract = "Vehicle crashworthiness is one of the key considerations in today's vehicle development program. The competitive environment requires carmakers to balance between achieving cost and time reduction while improving quality of their products. Quality here encompasses the safety performance in both preventing accidents from happening (active safety system) to protecting passengers from injuries (passive safety system). As reuse aims to sustain the function of old product or components for the second life, it will be necessary to preserve the materials. The other consideration is in terms of reusability of the beam as part of cost consideration especially in low impact scenario whereby deformation of the beam/structure may be minimal. In such cases, the damage or deformation has to be accessed to ascertain whether the beam can reused. This paper presents a study on the behavior of a door beam upon impact using Finite Element Analysis. The analyses include energy absorption characteristics, deformation and stress of the beam structure and also the effect of impactor on the crash characteristics of the door beam in terms of reusability. It was found that reusability is highly dependent on a number of factors such as the impactor kinetic energy (mass and speed) and materials characteristics. For metallic structure, reusability will be influenced by whether the material undergoes major permanent plastic deformation or behave within the elastic zone upon impact. Once the structure undergoes permanent plastic deformation reusability will not be possible. The results show that for impactor below 20kg, the beam of the car door will deform within the elastic region with the possibility of reusability. However, for load case 30kg and above, the beam undergoes permanent deformation which renders it useless after impact. Further investigation will be necessary to understand how different materials and geometry of the beam can improve the energy absorption characteristics and reduce damage of the car door assembly to enable reusability at the end of its life.",
keywords = "Assembly, Automotive component reuse, Durability and materials, Impact",
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AU - Abd. Wahab, Dzuraidah

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