The document discusses conducting a side pole impact test simulation using ANSYS software to analyze three materials - mild steel, aluminum alloy AA6060T4, and hot press formed Usibor 1500P - for a B-pillar panel. The simulation found that Usibor 1500P absorbed the most energy at 414.07 kJ/kg and allowed for 53.27% weight reduction compared to the benchmark mild steel. Aluminum AA6060T4 absorbed 299.52 kJ/kg and reduced weight by 51.54% compared to mild steel. The document provides background on B-pillar design, crashworthiness, hot press forming process, and the study's methodology for material selection and finite element analysis simulation.
In this research work, suitable lightweight material is found for chassis frame by analyzing chassis with different
materials like structural steel, aluminum alloy and Epoxy E-Glass UD composite materials. The selected material should have the
sufficient strength to carry the load coming on to the chassis when it is supporting the vehicle. With reduction in the weight of the
chassis, reduces the overall weight of the vehicle, which leads to the reduction in fuel. Thus, the usage of lightweight materials in
manufacturing of chassis frame has the advantages. The materials used should help in reducing the weight of the vehicle while
maintaining the necessary strength for supporting the expected load acting on the frame under various operating conditions.
ANSYS finite element software is used to analyze the performance of the chassis with different materials. The 3D model of the
chassis frame is developed by SOLIDWORKS software and numerical analysis is carried out by ANSYS. The model of the ladder
frame is developed using generic specifications. The FEM analysis was done on chassis frame for its deformation and stresses by
applying maximum load. The von-misses stresses, strain and deformations of the chassis with structural steel, aluminum alloy and
composite materials are compared. Composite materials are observed to be better with less weight with similar performance. It is
found that composite (E-glass) is more preferable material for chassis frame.
Engine is one of the most significant component of road vehicles. High performance vehicles have their
engine supported by bracket. The engine mounting plays an important role in reducing the noise and vibrations, improving the
comfort and work environment of a vehicle. The present work deals with design modification of engine mounting bracket.
Modelling work has been carried out with commercial desktop CAD software and analyzed the modal performance with
Analysis software. Ribs has been adopted to the existing mounting bracket for its better performance structural, thermal and
modal analysis has been carried out with analysis software. Aluminium alloy, aluminium silicon carbide and magnesium alloy
are considered as the different materials of mounting bracket. Based on the analysis it is found that the aluminium silicon
carbide is superior suited for the modified V6 engine mounting bracket.
ANALYSIS OF SPACE FRAME OF FORMULA SAE AT HIGH SPEED WITH ERGONOMIC AND VIBRA...IAEME Publication
This paper introduces a design and analysis methodology of space frame chassis in the context of ending new and innovative design principle by means of optimization techniques. The design is according to the Formula SAE International rule book. Our paper emphasis on the driver safety, ergonomics of the driver according to the rule book in which we calculate the critical conditions of the race track, emphasis on the vehicle head on collision, rear impact test, torsional rigidity test, vibrational analysis of roll cage (space frame chassis) and side impact to make that chassis under the design limits and having the factor of safety 1-2.5 having a material of chromoly 4130 which is selected as an optimum material for design.
A review of Carbon Nanotube Reinforced Aluminium Composite and Functionally ...IJMER
Material selection is a very critical issue when it comes to aerospace engineering. Materials
should have good qualities like light weight, high strength and corrosion resistance with economic
viability. Over the period, Aluminium blends of composite are used for variety of applications. Carbon
Nanotube reinforced Aluminium composites and Functionally graded composites(FGC ) are the new
developments in materials engineering. Gradual but continuous variation in composition and structure
over volume, results in corresponding changes in the properties of material in contrast to homogeneous
mixing of CNT in case of composite. FGM promises to be more suitable in the future. This paper focuses
on brief review of CNT reinforced Aluminium composite and FGM application in aerospace.
In this research work, suitable lightweight material is found for chassis frame by analyzing chassis with different
materials like structural steel, aluminum alloy and Epoxy E-Glass UD composite materials. The selected material should have the
sufficient strength to carry the load coming on to the chassis when it is supporting the vehicle. With reduction in the weight of the
chassis, reduces the overall weight of the vehicle, which leads to the reduction in fuel. Thus, the usage of lightweight materials in
manufacturing of chassis frame has the advantages. The materials used should help in reducing the weight of the vehicle while
maintaining the necessary strength for supporting the expected load acting on the frame under various operating conditions.
ANSYS finite element software is used to analyze the performance of the chassis with different materials. The 3D model of the
chassis frame is developed by SOLIDWORKS software and numerical analysis is carried out by ANSYS. The model of the ladder
frame is developed using generic specifications. The FEM analysis was done on chassis frame for its deformation and stresses by
applying maximum load. The von-misses stresses, strain and deformations of the chassis with structural steel, aluminum alloy and
composite materials are compared. Composite materials are observed to be better with less weight with similar performance. It is
found that composite (E-glass) is more preferable material for chassis frame.
Engine is one of the most significant component of road vehicles. High performance vehicles have their
engine supported by bracket. The engine mounting plays an important role in reducing the noise and vibrations, improving the
comfort and work environment of a vehicle. The present work deals with design modification of engine mounting bracket.
Modelling work has been carried out with commercial desktop CAD software and analyzed the modal performance with
Analysis software. Ribs has been adopted to the existing mounting bracket for its better performance structural, thermal and
modal analysis has been carried out with analysis software. Aluminium alloy, aluminium silicon carbide and magnesium alloy
are considered as the different materials of mounting bracket. Based on the analysis it is found that the aluminium silicon
carbide is superior suited for the modified V6 engine mounting bracket.
ANALYSIS OF SPACE FRAME OF FORMULA SAE AT HIGH SPEED WITH ERGONOMIC AND VIBRA...IAEME Publication
This paper introduces a design and analysis methodology of space frame chassis in the context of ending new and innovative design principle by means of optimization techniques. The design is according to the Formula SAE International rule book. Our paper emphasis on the driver safety, ergonomics of the driver according to the rule book in which we calculate the critical conditions of the race track, emphasis on the vehicle head on collision, rear impact test, torsional rigidity test, vibrational analysis of roll cage (space frame chassis) and side impact to make that chassis under the design limits and having the factor of safety 1-2.5 having a material of chromoly 4130 which is selected as an optimum material for design.
A review of Carbon Nanotube Reinforced Aluminium Composite and Functionally ...IJMER
Material selection is a very critical issue when it comes to aerospace engineering. Materials
should have good qualities like light weight, high strength and corrosion resistance with economic
viability. Over the period, Aluminium blends of composite are used for variety of applications. Carbon
Nanotube reinforced Aluminium composites and Functionally graded composites(FGC ) are the new
developments in materials engineering. Gradual but continuous variation in composition and structure
over volume, results in corresponding changes in the properties of material in contrast to homogeneous
mixing of CNT in case of composite. FGM promises to be more suitable in the future. This paper focuses
on brief review of CNT reinforced Aluminium composite and FGM application in aerospace.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
IMPACT ANALYSIS OF ALUMINUM HONEYCOMB SANDWICH PANEL BUMPER BEAM: A REVIEW ijiert bestjournal
Bumper is a energy absorbing protective element whi ch absorb the energy in front collision and protect valuable parts like radiator etc. Bumper is act like protect ive shield generally made of steel material. As eco nomic point of view and to reduce consumption of fuel manufacturin g of light weight vehicle is requirement of current situation. Application of composite material in automobile sec tor is now day common thing. Aluminum honeycomb san dwich panel is basically material from aerospace industri es and known for its high strength to weight ratio. Sandwich structure basically having its properties due to ge ometry. To determine various properties of sandwich structure conducting experiments is expensive,so generally F EA is used .However complex geometry is hurdle so t here are various theories are available for simplification o f model. These theories convert 3D model in to homo genous model .As far as concerning India manufacturing rate of s andwich structure is very less,so generally cost i s more. Greatest giant manufacturer is china we can observe their bu llet train and metro transport facility constructio n. Recently in march 2014 largest selling Indian cars are failed in NCap test in 100% frontal crash test. So requirement of more energy absorbing material with economy cons ideration is important.
The essential of car wheel rim is to provide a firm base on which to fit the tyre. Its dimensions, shape should be
suitable to adequately accommodate the particular tyre required for the vehicle. In this project a tyre of car
wheel rim belonging to the disc wheel category is considered. Design is an important industrial activity which
influences the quality of the product. The wheel rim is modeled by using modeling software catiav5r17. By
using this software the time spent in producing the complex 3- D models and the risk involved in the design and
manufacturing process can be easily minimized. So the modeling of the wheel rim is made by using CATIA.
Later this CATIA modal is imported to ANSYS WORKBENCH 14.5 for analysis work. ANSYS
WORKBENCH 14.5 is the latest software used for simulating the different forces, pressure acting on the
component and also calculating and viewing the results. By using ANSYS WORKBENCH 14.5 software
reduces the time compared with the method of mathematical calculations by a human. ANSYS WORKBENCH
14.5 static structural analysis work is carried out by considered three different materials namely aluminum alloy
,magnesium alloy and structural steel and their relative performances have been observed respectively. In
addition to wheel rim is subjected to modal analysis, a part of dynamic analysis is carried out its performance is
observed. In this analysis by observing the results of both static and dynamic analysis obtained magnesium alloy
is suggested as best material.
DESIGN AND COMPARATIVE ANALYSIS OF OLD & NEW MODEL CAR WHEEL RIMS WITH VARIOU...Journal For Research
The car wheel is the most important thing for load carrying element material even vehicle static and running conditions. Also wheel is affected by steering control and suspension. So we should consider all load acting on the vehicle drives. In our project, design and comparative analysis of old & new model car Wheel Rims. Here our new model rim is BMW Rim, other one old model rim is normal rim like ix35 Hyundai car rim) for more effective analysis. This project is tested to the wheel according to the specification given by the industrial standards, threes kind of test is performed. Later this solid works model is imported to Ansys for analysis work. in the material using aluminium alloy and stainless steel their relative performances have been observed respectively. In addition to this rim is subjected to vibration analysis (modal analysis), a part of dynamic analysis is carried out its performance is observed
Structural Analysis of Ladder Chassis Frame for Jeep Using Ansys IJMER
Automotive chassis frame is an important part of an automobile. The automotive chassis
frame is the structural backbone of any vehicle. The main function of chassis frame is to support the
body, different parts of an automobile and topayload placed upon it.The chassis frame has to withstand
the stresses developed as well as deformation occurs in it and to withstand the shock, twist vibration
and other stresses. Its principle function is to carry the maximum load for all designed operating
condition safelythat should be within a limit. On chassis, frame maximum shear stress and deflection
under maximum load are important criteria for design andanalysis. In these projects, we
havecalculated the von mises stress and shear stress for the chassis frame and the finite element
analysis has been donefor the validation on the chassis frame model of jeep. We have taken certain
material as Mild sheet steel, aluminium alloy and titanium alloy for the rectangular hollow box type to
design chassis frame of jeep.
Software used in this project, CATIA V5-[Product 1] for design purpose and ANSYS 14 is used for
analysis.
collision. There are number of wheel test are available in designing of rim to fulfill the safety requirements
and standards. The aim of this study was to analyze and study the structure for car wheel rim by using the
numerical method. The most of the test procedure has to comply with international standards, which establishes
minimum mechanical requirements and impact collision characteristics of wheels. Numerical implementation of
impact test is convenient for shorten the design time and lower development cost. In this study cast aluminium
alloy wheel rim are used for simulation of impact test by using 3–D explicit finite element methods. The design
of aluminium alloy wheel for automobile application which is carried out and paying special attention to
optimization of the shape and mass of the wheel rim according to aesthetical point of view, to overcome the
wheel cap. A finite element model of the wheel with its tire and striker were developed taking account of the
nonlinearity material properties. Simulation was conducted to study the stress and displacement distributions
during impact test. The analyses results are presented as a function of time. The study is carried under the above
constraints and the results are taken to carryout for further analysis i.e. shape and weight optimization of the
wheel.
Automotive design with economy and safety has been a great challenge to design engineers. The safety of the
passengers and vehicle during vehicle crashes can be ensured to a certain limit by using good bumpers. Bumper is an
important part of vehicle which acts as one of the safety part of vehicle, now a day’s bumper is used in vehicle which
directly connected to chassis of vehicle. So that when accidents are happened the force that transfer to other parts of
vehicle through linkage There is no mechanism to drop that linkage and to absorb that impact forces. So that the
development of a new bumper system by springs. Spring is used to minimize the impact of accidents and it will
resists or absorbs impact forces. The new bumper system will be design in CATIA and structural analysis is done by
ANSYS. For structural analysis of the bumper materials like Glass mat thermoplastics (GMT), carbon fiber
composite and aluminum B390 materials are used.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
IMPACT ANALYSIS OF ALUMINUM HONEYCOMB SANDWICH PANEL BUMPER BEAM: A REVIEW ijiert bestjournal
Bumper is a energy absorbing protective element whi ch absorb the energy in front collision and protect valuable parts like radiator etc. Bumper is act like protect ive shield generally made of steel material. As eco nomic point of view and to reduce consumption of fuel manufacturin g of light weight vehicle is requirement of current situation. Application of composite material in automobile sec tor is now day common thing. Aluminum honeycomb san dwich panel is basically material from aerospace industri es and known for its high strength to weight ratio. Sandwich structure basically having its properties due to ge ometry. To determine various properties of sandwich structure conducting experiments is expensive,so generally F EA is used .However complex geometry is hurdle so t here are various theories are available for simplification o f model. These theories convert 3D model in to homo genous model .As far as concerning India manufacturing rate of s andwich structure is very less,so generally cost i s more. Greatest giant manufacturer is china we can observe their bu llet train and metro transport facility constructio n. Recently in march 2014 largest selling Indian cars are failed in NCap test in 100% frontal crash test. So requirement of more energy absorbing material with economy cons ideration is important.
The essential of car wheel rim is to provide a firm base on which to fit the tyre. Its dimensions, shape should be
suitable to adequately accommodate the particular tyre required for the vehicle. In this project a tyre of car
wheel rim belonging to the disc wheel category is considered. Design is an important industrial activity which
influences the quality of the product. The wheel rim is modeled by using modeling software catiav5r17. By
using this software the time spent in producing the complex 3- D models and the risk involved in the design and
manufacturing process can be easily minimized. So the modeling of the wheel rim is made by using CATIA.
Later this CATIA modal is imported to ANSYS WORKBENCH 14.5 for analysis work. ANSYS
WORKBENCH 14.5 is the latest software used for simulating the different forces, pressure acting on the
component and also calculating and viewing the results. By using ANSYS WORKBENCH 14.5 software
reduces the time compared with the method of mathematical calculations by a human. ANSYS WORKBENCH
14.5 static structural analysis work is carried out by considered three different materials namely aluminum alloy
,magnesium alloy and structural steel and their relative performances have been observed respectively. In
addition to wheel rim is subjected to modal analysis, a part of dynamic analysis is carried out its performance is
observed. In this analysis by observing the results of both static and dynamic analysis obtained magnesium alloy
is suggested as best material.
DESIGN AND COMPARATIVE ANALYSIS OF OLD & NEW MODEL CAR WHEEL RIMS WITH VARIOU...Journal For Research
The car wheel is the most important thing for load carrying element material even vehicle static and running conditions. Also wheel is affected by steering control and suspension. So we should consider all load acting on the vehicle drives. In our project, design and comparative analysis of old & new model car Wheel Rims. Here our new model rim is BMW Rim, other one old model rim is normal rim like ix35 Hyundai car rim) for more effective analysis. This project is tested to the wheel according to the specification given by the industrial standards, threes kind of test is performed. Later this solid works model is imported to Ansys for analysis work. in the material using aluminium alloy and stainless steel their relative performances have been observed respectively. In addition to this rim is subjected to vibration analysis (modal analysis), a part of dynamic analysis is carried out its performance is observed
Structural Analysis of Ladder Chassis Frame for Jeep Using Ansys IJMER
Automotive chassis frame is an important part of an automobile. The automotive chassis
frame is the structural backbone of any vehicle. The main function of chassis frame is to support the
body, different parts of an automobile and topayload placed upon it.The chassis frame has to withstand
the stresses developed as well as deformation occurs in it and to withstand the shock, twist vibration
and other stresses. Its principle function is to carry the maximum load for all designed operating
condition safelythat should be within a limit. On chassis, frame maximum shear stress and deflection
under maximum load are important criteria for design andanalysis. In these projects, we
havecalculated the von mises stress and shear stress for the chassis frame and the finite element
analysis has been donefor the validation on the chassis frame model of jeep. We have taken certain
material as Mild sheet steel, aluminium alloy and titanium alloy for the rectangular hollow box type to
design chassis frame of jeep.
Software used in this project, CATIA V5-[Product 1] for design purpose and ANSYS 14 is used for
analysis.
collision. There are number of wheel test are available in designing of rim to fulfill the safety requirements
and standards. The aim of this study was to analyze and study the structure for car wheel rim by using the
numerical method. The most of the test procedure has to comply with international standards, which establishes
minimum mechanical requirements and impact collision characteristics of wheels. Numerical implementation of
impact test is convenient for shorten the design time and lower development cost. In this study cast aluminium
alloy wheel rim are used for simulation of impact test by using 3–D explicit finite element methods. The design
of aluminium alloy wheel for automobile application which is carried out and paying special attention to
optimization of the shape and mass of the wheel rim according to aesthetical point of view, to overcome the
wheel cap. A finite element model of the wheel with its tire and striker were developed taking account of the
nonlinearity material properties. Simulation was conducted to study the stress and displacement distributions
during impact test. The analyses results are presented as a function of time. The study is carried under the above
constraints and the results are taken to carryout for further analysis i.e. shape and weight optimization of the
wheel.
Automotive design with economy and safety has been a great challenge to design engineers. The safety of the
passengers and vehicle during vehicle crashes can be ensured to a certain limit by using good bumpers. Bumper is an
important part of vehicle which acts as one of the safety part of vehicle, now a day’s bumper is used in vehicle which
directly connected to chassis of vehicle. So that when accidents are happened the force that transfer to other parts of
vehicle through linkage There is no mechanism to drop that linkage and to absorb that impact forces. So that the
development of a new bumper system by springs. Spring is used to minimize the impact of accidents and it will
resists or absorbs impact forces. The new bumper system will be design in CATIA and structural analysis is done by
ANSYS. For structural analysis of the bumper materials like Glass mat thermoplastics (GMT), carbon fiber
composite and aluminum B390 materials are used.
Design and Optimisation of Sae Mini Baja ChassisIJERA Editor
The objective is to design and develop the roll cage for All - Terrain Vehicle accordance with the rulebook of BAJA 2014 given by SAE. The frame of the SAE Baja vehicle needs to be lightweight and structurally sound to be competitive but still protect the driver. The vehicle needs to traverse all types of off-road conditions including large rocks, downed logs, mud holes, steep inclines, jumps and off camber turns. During the competition events there is significant risk of rollovers, falling from steep ledges, collisions with stationary objects, or impacts from other vehicles. Material for the roll cage is selected based on strength and availability. A software model is prepared in Pro-engineer. Later the design is tested against all modes of failure by conducting various simulations and stress analysis with the aid of ANSYS 13. Based on the result obtained from these tests the design is modified accordingly. A target of 2 is set for Yield Factor of Safety.
This paper discusses the development of composite materials applications in the performance automotive industry and how the advances made can affect the commercial automotive industry.
INVESTIGATION OF COMPOSITE TORSION SHAFT USING MATERIAL MATRIX IN FEAIjripublishers Ijri
have found application in many areas of daily life for quite some time. Often it is not realized that the application makes
use of composite materials.
This research attempt is made to evaluate the sustainability of composite material such as FRP (fiber rein forced polymer)
and CRFP (carbon reinforced fiber polymer) epoxy/glass for the purpose of automotive transmission application
using finite element method in Ansys.
Initially literature review will be done to understand the approach.
3D model will be prepared to carryout analysis on model.
Structural and vibrational analysis will be done by implementing different layer orientations on FRP & CRFP’S.
The Team Member and Guest Experience - Lead and Take Care of your restaurant team. They are the people closest to and delivering Hospitality to your paying Guests!
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408-784-7371
Foodservice Consulting + Design
Artificial intelligence (AI) offers new opportunities to radically reinvent the way we do business. This study explores how CEOs and top decision makers around the world are responding to the transformative potential of AI.
Oprah Winfrey: A Leader in Media, Philanthropy, and Empowerment | CIO Women M...CIOWomenMagazine
This person is none other than Oprah Winfrey, a highly influential figure whose impact extends beyond television. This article will delve into the remarkable life and lasting legacy of Oprah. Her story serves as a reminder of the importance of perseverance, compassion, and firm determination.
Senior Project and Engineering Leader Jim Smith.pdfJim Smith
I am a Project and Engineering Leader with extensive experience as a Business Operations Leader, Technical Project Manager, Engineering Manager and Operations Experience for Domestic and International companies such as Electrolux, Carrier, and Deutz. I have developed new products using Stage Gate development/MS Project/JIRA, for the pro-duction of Medical Equipment, Large Commercial Refrigeration Systems, Appliances, HVAC, and Diesel engines.
My experience includes:
Managed customized engineered refrigeration system projects with high voltage power panels from quote to ship, coordinating actions between electrical engineering, mechanical design and application engineering, purchasing, production, test, quality assurance and field installation. Managed projects $25k to $1M per project; 4-8 per month. (Hussmann refrigeration)
Successfully developed the $15-20M yearly corporate capital strategy for manufacturing, with the Executive Team and key stakeholders. Created project scope and specifications, business case, ROI, managed project plans with key personnel for nine consumer product manufacturing and distribution sites; to support the company’s strategic sales plan.
Over 15 years of experience managing and developing cost improvement projects with key Stakeholders, site Manufacturing Engineers, Mechanical Engineers, Maintenance, and facility support personnel to optimize pro-duction operations, safety, EHS, and new product development. (BioLab, Deutz, Caire)
Experience working as a Technical Manager developing new products with chemical engineers and packaging engineers to enhance and reduce the cost of retail products. I have led the activities of multiple engineering groups with diverse backgrounds.
Great experience managing the product development of products which utilize complex electrical controls, high voltage power panels, product testing, and commissioning.
Created project scope, business case, ROI for multiple capital projects to support electrotechnical assembly and CPG goods. Identified project cost, risk, success criteria, and performed equipment qualifications. (Carrier, Electrolux, Biolab, Price, Hussmann)
Created detailed projects plans using MS Project, Gant charts in excel, and updated new product development in Jira for stakeholders and project team members including critical path.
Great knowledge of ISO9001, NFPA, OSHA regulations.
User level knowledge of MRP/SAP, MS Project, Powerpoint, Visio, Mastercontrol, JIRA, Power BI and Tableau.
I appreciate your consideration, and look forward to discussing this role with you, and how I can lead your company’s growth and profitability. I can be contacted via LinkedIn via phone or E Mail.
Jim Smith
678-993-7195
jimsmith30024@gmail.com
The case study discusses the potential of drone delivery and the challenges that need to be addressed before it becomes widespread.
Key takeaways:
Drone delivery is in its early stages: Amazon's trial in the UK demonstrates the potential for faster deliveries, but it's still limited by regulations and technology.
Regulations are a major hurdle: Safety concerns around drone collisions with airplanes and people have led to restrictions on flight height and location.
Other challenges exist: Who will use drone delivery the most? Is it cost-effective compared to traditional delivery trucks?
Discussion questions:
Managerial challenges: Integrating drones requires planning for new infrastructure, training staff, and navigating regulations. There are also marketing and recruitment considerations specific to this technology.
External forces vary by country: Regulations, consumer acceptance, and infrastructure all differ between countries.
Demographics matter: Younger generations might be more receptive to drone delivery, while older populations might have concerns.
Stakeholders for Amazon: Customers, regulators, aviation authorities, and competitors are all stakeholders. Regulators likely hold the greatest influence as they determine the feasibility of drone delivery.
Case Analysis - The Sky is the Limit | Principles of Management
A290109
1. American International Journal of Business Management (AIJBM)
ISSN- 2379-106X, www.aijbm.com Volume 2, Issue 9 (September- 2019), PP 01-09
*Corresponding Author: 1
Saeed Mohamed Ahmed ww.aijbm.com 1 | Page
B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT
ANALYSIS
1
Saeed Mohamed Ahmed, 2
Sadik AlmahdiSadik Omar, 3
Saleh Mohsen Albakri
1,2,3
Faculty of Engineering Science and Technology Infrastructure, Infrastructure University Kuala Lumpur.
*Corresponding author: Saeed Mohamed Ahmed
ABSTRACT:- In this project the objective is to improve the B-pillar that is made of mild steel (192), in term
of specific energy absorption and weight reduction. The conventional material mild steel needs to be change to
other material that can absorb more energy during collision and reduce the injury level of driver and occupant.
Three Side pole impact test will be conducted using ANSYS simulation software for three materials Mild steel
(192), aluminum AA (6060T40) and hot press formed Usibor (1500P). side pole impact test will be carried out
according to FMVSS 214 role and regulation car moving at 32.2 km/h (20 mph) at an angle of 75 degrees
crashes into a fixed rigid pole that is 254 mm diameter.
The following are the result for the simulation in result of directional deformation
Throughout the tree materials Usibor (1500P) B-pillar had the maximum energy absorption that reach 414.07
KJ/Kg. aluminum AA B-pillar (6060T4) comes in second place with 299.52 KJ/Kg. benchmark model mild
steel (MAT192) had the lowest energy absorption with result of 212.48 KJ/Kg. Using Usibor (1500P) in B-
pillar lead to reduction in weight that reach about 53.27%. in the other hand aluminum AA (6060T4) weight
reduction reached 51.54% compared with commercialize B-pillar mild steel (MAT192).
Usibor (1500P) showed great energy absorption and helped in reducing the weight of Bpillar and it will be the
perfect selection in replacing the benchmark model B-pillar mild steel (MAT192).
Keywords: B-Pillar, Panel, Side Pole.
I. INTRODUCTION
With the development of society, people have more and more stringent demands for automobile
passive safety and fuel economy, which requires the improvement of automobile structure crashworthiness and
light weighting degree. The automobile body light weighting can be achieved by structure modification or
material replacement. The automobile body structure modification requires the changes of forming, welding and
assembling systems which is costly, while material replacement needs fewer such changes.
High strength steel sheet can be used in automobile body to improve the B-pillar
component’simpactenergyabsorbingcapacityandresistancetoplasticdeformation.The B-pillar is an essential load-
carrying element in any automobile framework. It functions as a primary supporting structure for the roof. It is
characterized by a thin- walled,seam-welded,closed-sectionedstructuremadefromsteels.TheB-pillarislocated
between the front and rear doors of vehicle. It consists of three components, named as B- pillarinnerplate,B-
pillarreinforcementplate,andB-pillarouterplate.Atpresent,forthe B-pillar of most vehicles, the metal is the
preferredmaterial.
The finite element model of B-pillar is shown in Fig. 1.1 The B-pillar is usually designed to achieve
the high resistance and rigidity in the region door hinges and door locks. It can guarantee the living space of the
driver and reduce the direct damage of occupantinasideimpact. It also should have enough strength to resist
deformation in the case of the roofcrush.
2. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
*Corresponding Author: 1
Saeed Mohamed Ahmed ww.aijbm.com 2 | Page
B-pillar
Figure1: B-Pillar Locations
Hot press forming–also known as press is hardening–is are latively new forming process. It was
recently developed particularly for the application of high strength steels in car body manufacturing in the
automotive industry. Hot forming is a unique metal forming processing technique. In this process the material is
heated up to a sufficiently hightemperaturetoprovideausteniticmicrostructurethenitiscooleddownrapidlyinthe
formingtool.
At certain cooling rate diffusion less, martensitic phase transformation occurs leading to significant
increase of the strength parameters. Since the martensitic transformation – i.e. the hardening process – occurs in
the forming tool, this is thereason that this process is often termed as press hardening. Press hardening allows
raising the strength level up to around 2000 MPA enabling weight reduction of 20 to 30% without
safetycompromiseandcostincrease.Examplesofmaterialsusedinhotpressformingare mild steel, aluminum,
magnesium and high strengthsteel.
Crashworthiness features includes air bags, seat belts, crumple zones, side impact protection interior
padding and headrests. These feature sareup dated when the reis a new safer and better design. The impotence
of Crashworthiness features, which are designed to minimize occupant injuries, prevent ejection from the
vehicle, andreduce the risk offire, include: seat belts; crumple zones; and, airbags (including side
impactprotection).
ProblemStatement
Demand for automobile passive safety and fuel economy requires improvement of automobile structure
crashworthiness and light weighting degree. The conventional material (mild steel) need to be improved and
changed with material that can absorb more energy during collision to reduce the injury level of driver and
occupant. Also, the continues need for improving the B-Pillar crashworthiness in term of specific energy
absorption and weightreduction.
Objectives of the study
The aim of this project is to:
a. To compare Aluminum (AA6060 T4) and hot press form (HPF Usibor® 1500P) with benchmark
model B-pillar mild steel (MAT192) in term of specific energy absorption by using finite elementmodel.
b. To improve the material type for the B-Pillar system to achieve minimumweight.
Scope of the study
a. Literature study on hot press forming (HPF) specifically onB-pillar.
b. Selection of materials used in this project such as benchmark model Mild steel (MAT 192), Aluminum
(AA6060 T4) and hot press form (HPF Usibor®1500P).
c. Crashworthiness of the B-pillar specifically on specific energy absorption (SEA) and weightreduction.
d. Conductsidepoleimpacttestsimulationbyusingfiniteelementanalysissoftware.
3. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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II. LITERATURE REVIEW
The AutomobileStructure:
Safety engineers design and manufacture vehicle body structures to withstand static and dynamic
service loads encountered during the vehicle life cycle. Exterior shapes provide low aerodynamic drag
coefficient. The interior provides adequate space to comfortably
accommodateitsoccupants.Thevehiclebodytogetherwiththesuspensionisdesignedto minimize eroad vibrations
and aero dynamic noise transfer to the occupants. In addition, the vehicle structure is designed to maintain its
integrity and provide adequate protection in survivable crashes. (Farley et al, 1992)
Thebody-overframestructureofapassengercarorasportutilityvehicleconsists of a vehicle body, frame, and front
sheet metal. Alight duty truck consists of a frame, cab,
andbox.Thevehiclebodyprovidesmostofthevehiclerigidityinbendingandintorsion. In addition, it provides a
specifically designed occupant cell to minimize injury in the event of crash. The chassis frame supports the
engine, transmission, power train, suspension and accessories. In front a impact, the frame and front sheet metal
absorb most of the crash energy by plastic deformation. The three structural modules are bolted together to form
the vehicle structure. The vehicle body is attached to the frame by shock absorbing body mounts, designed to
isolate from high frequency vibrations. Figure 2.1 is a photograph showing a typical vehicle with this type
ofstructure.
Figure 2: Typical Body-on-Framevehicle
B-pillar systemliterature:
The B-pillar is an essential load-carrying element in any automobile framework. It functions as a
primary supporting structure for the roof. It is characterized by a thin- walled, seam-welded, closed-sectioned
structure made from high strength steels (Jambor and Beyer, 1997).
B-Pillar is the pillar presents on both sides of a given vehicle between the rear and frontdoors.TheB-
Pillarmountedonavehicleforlatchingofthefrontdoorsandinstalling hinges for the rear doors is a steel structure
welded firmly on one end to the rocker panel and floor pan at the bottom of a vehicle while the other to the roof
rail for rigidity and support to the roofpanel
B-Pillar is the pillar presents on both sides of a given vehicle between the rear and frontdoors.
TheB-Pillarmountedonavehicleforlatchingofthefrontdoorsandinstalling hinges for the rear doors is a
steel structure welded firmly on one end to the rocker panel and floor pan at the bottom of a vehicle while the
other to the roof rail for rigidity and support to the roofpanel
4. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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Figure3: B-pillar component
Figure3: show the component of B-pillaritgoes as the following sidepartinterior back, B-pillar reinforcement, B-
pillar interior, side part external and preparation seat belt retractor.
Figure4: B-pillar component and arrangement to vehicle (Z. Yang, Q. Peng, J. Yang)
The A, B and C Pillars are designated (2), (3) and (4) and are attached together by the process of
welding to the floor panla belled as(1).Also, theroofrailorpanellabeled (5) is welded to the upper mostend of the
B-pillar. Furthermore, other part soft he B-pillar labelled. 6, this consist of a curved-like member labelled (7),
while the center flange is labelled (8), the two web-like segments labelled (9) and 10 and both side flanges
designated as (11) and(12).
The lower and upperendsectionlabelled(13)and(14)are the segments connecting the floor pan and the roof rail.
Moreover, the length (L) signifies the softer area of lateral flanges11and12oftheB-
pillar.Itisabout50%oftheentirelengthoftheflangesonthe side (Z. Yang, 2012).
III. CRASHWORTHINESS:
The ability of the vehicle to absorb energy and to prevent occupant injuries in the event of an accident
is referred to as ―Crashworthiness‖ (Farley,1992). The vehicle must be designed such that, at higher speeds its
occupants do not experience a net deceleration greater than 20 g. Crashworthiness can be categorized into three
basic areas, materials engineering and design, combustion and fire and finally medical engineering
(biomechanics).
5. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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It covers civil, automotive, military, marine and aerospace oriented applications, where the automotive
sector is probably the most prominent area in this respect. Crashworthiness features includes air bags, seat belts,
crumple zones, side impact protection,interiorpaddingandheadrests.Thesefeaturesareupdatedwhenthereisanew
safer and better design. Crashworthiness is not the same as vehicle safety, and the two topics must be
distinguished.
The safety of a vehicle depends on crashworthiness and as well as the accident avoidance features,
which might include ABS, good handling
characteristicsorevenoversizetires.Onevehiclemightbesaferstatisticallythananother and still have a significant
crashworthiness defect. It could even conceivably be less crashworthy overall while still being a "safer" vehicle.
Structural crashworthiness involves absorption of kinetic energy by considering designs and materials suitable
for controlled and predictive energy absorption. In this process, the kinetic energy of the colliding bodies is
partly converted into internal work.
Crash events are non-linear and may involve material failure, global and local structural instabilities
and failure of joints. In addition, strain-rate and inertia effects may play an important role in the response of the
structures involved.
The Hot Forming Process:
As it was very shortly described in the Introduction section, hot press forming is a complex forming
and tempering operation when the materials heated first up to the austeniticzone and holding until the carbon
fully dissolve producing homogeneous austenite microstructure. The forming operation is performed in this
state, and then the part is cooled down rapidly in the tool with the critical cooling rate to prevent the carbon
diffusion, thus resulting in martensiticmicrostructure.
The Hot Forming Process:
AsitwasveryshortlydescribedintheIntroductionsection,hotpressformingisacomplex forming and
tempering operation when the materials heated first up to the austeniticzone and holding until the carbon fully
dissolve producing homogeneous austenite microstructure. The forming operation is performed in this state, and
then the part is cooled down rapidly in the tool with the critical cooling rate to prevent the carbon diffusion, thus
resulting in martensiticmicrostructure.
Throughthecombinationofheating,holding,formingandrapidcooling,complex parts can be produced
with excellent strength properties. The usual process cycle of hot press forming can be seen inFigure 5.
Figure 5: Temperature vs. Process time for Hot Press Forming
Here are two main technological process variantsappliedin hot press forming: one of them is called
direct hot forming, the other is the indirect hot forming as shown in FiguresIn direct (or often termed
as single stage) hot press forming the blanksheetisdirectlyausterities,transferredtothe
Stampingtoolandcooleddownrapidly with the forming tool, thus providing the excellent strengthproperties.
6. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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Features Geometry
Meshing
Geometric Properties
Material Properties
Contact Interface
Boundary Conditions
Initial Velocity
Preparing the Analysis
Design and analysis of B-pillar in low speed pole impacttest:
Its importance to occupant safety makes the B-pillar an essential component in the crash worthiness of vehicle
side impact. However, this necessitates the complex nature of a B-pillar design with respect to high impact
resistance against unforeseen side collision of vehicles. The position of the B-pillar in a vehicle makes it very
important in the provision of high impact resistance and safety to vehicle occupants in crash events that involve
side
impact.However, strengthening or reinforcing structural members is more advantageous
thansubstitutingwithneworredesignedmembersassufficientresistanceagainstexternal load can be achieved
(Karbasian,H, Tekkaya, 2010).
Mostsideimpactscanbeclassifiedintotwotypes;car-to-broad-objectandcar-to- narrow-object. B-Pillars
are often designed to withstand side impact forces and remain elastic after the impact hasoccurred.
Crash impact analysis usually unravels the effects of linear static forces acting on vehicular structures in terms
of energy absorption and deformation upon low and high- velocity impacts.
Research Methodology:
This chapter explains the scientific method and technique used to carry out the thesis
projectanalysis.Firstthingtodoistoselectnewmaterialtoimprovethecrashworthiness ofB-
Pillarinthevehicle.Asabenchmarkmodelbeentakenforexaminationandanalysis which is the B-Pillar CAD of the
vehicle will be extruded based on the exact dimension
All the information must be clearly obtained especially the dimension of the current mild steel B-Pillar
model. It is important to identify the problem to avoid any failure in this project so that the project can be
successfully done and completed. For the literaturereviewpart,
alltheinformationwillbewritteninourresearchprogressasitwill help in producing the material replacement effect
onB-Pillar.
Steps of Carrying thesimulation:
Figure 6: steps of preparing model
7. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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Feature geometry:
This section normally talks about development of model feature, since in this project model is
imported and not developed from zero. The model consists of B-pillar (inner layer, outer layer, reinforcing
plate) that was provided solid works drawing software was used to draw the rigid pole by student.
Meshing:
Once the geometry is in an appropriate state, a mesh will be created to approximate the geometry this
meshing step is crucial to the finite element analysis as the quality of the
meshdirectlyreflectsonthequalityoftheresultsgenerated.Atthesametimethenumber of elements (number of nodes)
affects the computationtime.
Geometricproperties:
The section type of shell is assigned to the geometry, the analysis is then carried out as 3D analysis.
Complete key in the material manager, Section manager (section manager>shell category>mass part> thickness
> material). Complete the information about the section assignment (material manager > parameters> density>
Young Modulus> Strain > Poisson Ratio).
Preparing foranalysis:
For the last step in solution part insert deformation directional in X axis >Total deformation>
Equivalent stress >Solve. After a finite element model has been prepared and checked, boundary conditions
have been applied, and the model will be solved, it is time to investigate the results of the analysis. This activity
is known as the post- processing phase of the finite elementmethod.
3DModeling:
Figure 6: 3D modeling of B-pillar
Figure 6: show parts that B-pillar contain, and they are inner layer, reinforcement plate and outer layer.
And all the parts were provided.
IV. RESULT AND DISCUSSION:
The table show the number of node and element in all parts including inner layer1, inner layer 2, outer
layer, reinforced 1, reinforced 2 and the main structure, the total number nodes is 9992, for elements its 9030.
Table1 Number of Node and Element in Simulation
Part name Node Element
Inner 1 879 774
Inner 2 990 736
Outer 1580 1436
Reinforced 1 488 422
Reinforced 2 197 163
Main structure 5858 5499
8. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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Figure 7: Mesh of B-Pillar and Rigid Pole
The finite element analysis depends on the accuracy of meshing, a coarse mesh is chosen for this simulation to
ensure the accuracy of the result, Rigid pole mesh type is Quad/Tri.
Result of Directional Deformation in XAxis:
Figure 8: Ansys simulation results (X Axis directional deformation)
Figure 8 show the result of directional deformation for the commercialize B-pillarMild Steel (MAT192).
reinforcement layer with thickness of 1.6 mm, first simulation run according to FMVSS214 regulation, the
speed was set up to 32.2 km/h. the maximum directional deformation B-pillar was 0.021786m and minimum
was -0.014763 m, the calculation time was0.01s.
V. CONCLUSION AND RECOMMENDATION
In this study, the objective was to improve current benchmark model B-pillar mild steel (MAT 192) in
term of specific energy absorption and weight reduction. Side pole crash simulation was conducted to see which
material will absorb more energy during the crash, FMVSS 214 role and regulation were followed during
9. B-PILLAR PANEL SUBJECTED TO SIDE POLE IMPACT ANALYSIS
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conducting the simulation, the following points are the conclusion of thisstudy.
a. In result of directional deformation Usibor (1500P) showed slight improvement with result of
0.021403m, where commercialize mild steel (MAT192) and aluminum AA (6060T4) had the same directional
deformation of0.021786m.
b. Intermoftotaldeformation,Usibor(1500P)hadthelowestdeformationcompared with rest of the materials,
with deformation of 0. 11186m. in second place comes mildsteel (MAT192) with deformation of
0.11355m.aluminumAA(6060T4) had the heights deformation in all materials that reached0.11426m.
c. ThroughoutthetreematerialsUsibor(1500P)hadthemaximumenergyabsorption
thatreach74.71KJ/Kg.aluminumAA(6060T4)comesinsecondplacewith55.66
Recommendation
The following recommendation for future work can be noted:
a. Material other thenUsibor (1500P) can be used to improve specific energy absorption and reduce
weight ofB-pillar.
b. The speed used in side pole crash simulation can increased to see how materials will react athighspeed.
c. Experimental tests can be carried out to find the accuracy of the resultobtained
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*Corresponding author: Saeed Mohamed Ahmed
1
Faculty of Engineering Science and Technology Infrastructure,
Infrastructure University Kuala Lumpur.