UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

ULSAB Final Report
All simulations were run to their completion. Test and full vehicle
mass was assumed to be 1612 kg, which included luggage at 113
kg and occupants at 149 kg.
Analysis was performed with models of the following size:
Model definition
static front side rear roof
half impact impact impact crush
model and half
Number
offset model
of elements 54,521 178,386 181,963 90,105 119,226
Nodes 53,460 174,532 179,918 88,769 117,053
ULSAB was designed to meet five crash requirements:
35 MPH NCAP 0 DEGREE FRONTAL (FMVSS 208)
The conditions for the front crash analysis are based on several
requirements. In the ULSAB project, the focus was on
progressive crush of the upper and lower load path; sequential
stack up of the bumper, radiator and powertrain; integrity between
individual components; ‘A’ pillar displacement; definition of the
door opening; uniform distribution of the load; toe pan intrusion;
and passenger compartment residual space. These requirements
contribute to occupant safety and reflect the United States
Federal Motor Vehicle Safety Standard, FMVSS 208.
Analysis was set up as shown. The maximum deformation image
shows the deformed structure at event completion, which
occurred at 67 msec. The crash pulse can be seen in the graph
below. The table below lists the major events that occur during
the simulation. Maximum footwell intrusion was 94 mm. Peak
deceleration was approximately 31 g’s. Maximum dynamic crush
was approximately 620 mm.
35 mph NCAP set up 35 mph NCAP maximum deformation
31