Impact Testing and Modeling of DP600 Front Rails Tau Tyan
Impact Testing and Modeling of DP600 Front Rails Tau Tyan
Impact Testing and Modeling of DP600 Front Rails Tau Tyan
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<strong>Impact</strong> <strong>Testing</strong> <strong>and</strong> <strong>Modeling</strong> <strong>of</strong><br />
<strong>DP600</strong> <strong>Front</strong> <strong>Rails</strong><br />
<strong>Tau</strong> <strong>Tyan</strong><br />
Ford Motor Company<br />
w w w . a u t o s t e e l . o r g
Automotive Center<br />
US Steel<br />
• Gu<strong>of</strong>ei Chen<br />
• Ming Chen<br />
• Ming Shi<br />
w w w . a u t o s t e e l . o r g<br />
Contribution<br />
NAE Truck Safety<br />
Ford Motor Company<br />
• Meagan Gonzalez<br />
• Karthik Chitoor<br />
• Heung-Soo Kim<br />
• Yijung Chen<br />
• Miinshiou Huang<br />
• Matt Maltarich<br />
• Timothy Bailey<br />
• Dennis Heinanen
w w w . a u t o s t e e l . o r g<br />
Outline<br />
• Introduction – Generic Cross-section<br />
• <strong>DP600</strong> Multicorner Columns in Axial Crush<br />
• <strong>DP600</strong> Multicorner Columns in Side Bending<br />
• <strong>DP600</strong> 12 Corner Columns in Full Vehicle<br />
<strong>Front</strong>al <strong>Impact</strong> Application<br />
• Conclusions
•SUV/Truck Frame<br />
• CAE <strong>Modeling</strong><br />
• <strong>DP600</strong><br />
•Weight Optimization<br />
•Geometry<br />
• Material<br />
• Thickness<br />
• Cross-section<br />
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Introduction
Generic Cross-section Comparison<br />
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Dynamic Crush Mode Comparison<br />
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Outline<br />
• Introduction – Generic Cross-section<br />
• <strong>DP600</strong> Multicorner Columns in Axial Crush<br />
• <strong>DP600</strong> Multicorner Columns in Side Bending<br />
• <strong>DP600</strong> 12 Corner Columns in Full Vehicle<br />
Application<br />
• Conclusions
<strong>DP600</strong> Multicorner Columns in Axial Crush<br />
<strong>DP600</strong> (a) Hexagonal <strong>and</strong> (b) Octagonal rails <strong>of</strong> thickness 1.5mm.<br />
(a) 56 mm (2.205”) 120 º 56 mm (2.205”)<br />
(b)<br />
Outer<br />
28 mm (1.102”)<br />
Apply wel ds<br />
along the edge<br />
120 º for all angles<br />
120 º<br />
All dimensions are measured between outside surfaces<br />
120 º<br />
54.3 mm (2.138”)<br />
120 º<br />
97.0 mm (3.819”)<br />
112.9 mm (4.445”)<br />
Inner<br />
54.3 mm (2.138”)<br />
28 mm (1.102”)<br />
36 mm (1.417”)<br />
28 mm (1.102”)<br />
Apply welds<br />
along the edge<br />
t(mm) YS(MPa) TS(MPa) n El(%)<br />
1.5 392 696 0.868 13.6<br />
Mechanical properties <strong>of</strong> <strong>DP600</strong><br />
Strain rate data<br />
for <strong>DP600</strong>.<br />
21 mm (0.827”)<br />
Apply welds<br />
along the edge<br />
1200.0<br />
1000.0<br />
800.0<br />
600.0<br />
400.0<br />
200.0<br />
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True stress in MPa<br />
0.0<br />
Outer<br />
42 mm (1.653”)<br />
All dimensions are measured between outside surfaces<br />
29 mm (1.142”)<br />
135º<br />
42 mm (1.653”)<br />
135º<br />
21 mm (0.827”)<br />
40.8 mm (1.606”) 40.8 mm (1.606”)<br />
135º<br />
135º<br />
40.8 mm (1.606”)<br />
102.9 mm (4.051”)<br />
102.0 mm (4.016”)<br />
Inner<br />
29 mm (1.142”)<br />
42 mm (1.653”)<br />
<strong>DP600</strong>-Material curves - plastic portion<br />
Apply welds<br />
along the edge<br />
21 mm (0.827”)<br />
0.005 0.1 10 100 500 SHB1000<br />
0.0000 0.0500 0.1000 0.1500 0.2000 0.2500<br />
True strain
Axial Crush Test Setup<br />
Speed Machine Attached mass<br />
1 in/min Tinius Olsen N/A<br />
15 mph VIA Sled 2999 lbs<br />
30 mph VIA Sled 548 lbs<br />
Quasi-static test setup Dynamic test setup<br />
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CAE Methodology<br />
The following effects are included in the model:<br />
• Dimensions <strong>and</strong> thickness were measured from actual parts<br />
(sample size = 3)<br />
• Material properties were taken from coupon tests <strong>and</strong> input<br />
using Radioss type 36 material law<br />
• Forming <strong>and</strong> welding effects are considered in the model<br />
• Strain rate effect is also included in the model with tabulated<br />
material law
• Hexagonal Quasi-static Axial Crush<br />
CAE & Test Comparison<br />
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• Octagonal Quasi-static Axial Crush<br />
CAE & Test Comparison<br />
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• Hexagonal 15mph Axial Crush<br />
CAE & Test Comparison<br />
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• Octagonal 15mph Axial Crush<br />
CAE & Test Comparison<br />
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• Hexagonal 30mph Axial Crush<br />
CAE & Test Comparison<br />
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• Octagonal 30mph Axial Crush<br />
CAE & Test Comparison<br />
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1 Element<br />
formulation<br />
Sensitivity Study <strong>of</strong> Axial Crush Parameters<br />
Variable Value<br />
2 Friction coefficient<br />
3 Mesh size<br />
4 Strain rate<br />
5 Corner/weld<br />
properties<br />
6 Gage<br />
7 Initial velocity<br />
8 Shape change<br />
9 Tilt angle<br />
Effect on peak<br />
force<br />
15mph 30mph<br />
Effect on crush<br />
distance<br />
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Effect on peak<br />
force<br />
Effect on crush<br />
distance<br />
Belytschko-Tsay element - - - -<br />
QEPH element decrease increase decrease increase<br />
QPPS element increase decrease increase decrease<br />
0.3 - - - -<br />
0.1 none none none increase<br />
5.0mm - - - -<br />
2.5mm none increase increase decrease<br />
Strain rate properties - - - -<br />
No strain rate properties decrease increase decrease increase<br />
Corner + weld properties - - - -<br />
Weld properties only none none none increase<br />
Forming properties only none none none increase<br />
No forming/weld properties none none increase increase<br />
1.5mm - - - -<br />
1.65mm increase decrease increase decrease<br />
1.35mm decrease increase decrease increase<br />
15mph - - - -<br />
14mph none decrease none none<br />
16mph none increase none increase<br />
nominal - - - -<br />
oblong none none decrease increase<br />
0 degrees - - - -<br />
0.1 degrees none none none decrease<br />
0.2 degrees none increase none decrease
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Outline<br />
• Introduction – Generic Cross-section<br />
• <strong>DP600</strong> Multicorner Columns in Axial Crush<br />
• <strong>DP600</strong> Multicorner Columns in Side Bending<br />
• <strong>DP600</strong> 12 Corner Columns in Full Vehicle<br />
<strong>Front</strong>al <strong>Impact</strong> Application<br />
• Conclusions
Striker 2" o.d..<br />
560 mm<br />
700 mm<br />
1in/min<br />
Lateral Bending Test Setup<br />
3/8” thickness<br />
Crush<br />
Type<br />
Hexagonal <strong>and</strong> Octagonal quasi-static <strong>and</strong> dynamic bending test fixture<br />
w w w . a u t o s t e e l . o r g<br />
Machine Speed<br />
Attached<br />
Mass<br />
Quasistatic Tinius Olsen 1 in/ min N/A<br />
Dynamic Bendix 30 mph 77 lbs
CAE <strong>and</strong> Test Crush Mode Comparison<br />
Hexagonal & Octagonal 30mph lateral bending<br />
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CAE <strong>and</strong> Test Comparison<br />
Hexagonal <strong>and</strong> Octagonal quasistatic bending<br />
Hexagonal <strong>and</strong> Octagonal 30mph lateral bending<br />
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Energy Comparison<br />
Hexagonal <strong>and</strong> Octagonal quasistatic bending Hexagonal <strong>and</strong> Octagonal dynamic bending
Variable Value Effect on Peak Force<br />
Element Formulation<br />
Friction Coefficient<br />
Mesh Size<br />
Strain Rate<br />
Forming / Weld Properties<br />
Gage<br />
Initial Velocity<br />
Sensitivity Study <strong>of</strong> Axial Crush Parameters<br />
Belytschko-Tsay Element -<br />
QEPH Element Increase<br />
QPPS Element Increase<br />
0.3 None<br />
0.1 -<br />
5.0 mm -<br />
2.5 mm Increase<br />
Strain Rate Properties -<br />
No Strain Rate Properties Decrease<br />
Forming + Weld Properties -<br />
No Weld Properties None<br />
No Forming Properties Decrease<br />
No forming / Weld Properties Decrease<br />
1.5 mm -<br />
1.65 mm Increase<br />
1.35 mm Decrease<br />
30 mph -<br />
29 mph None<br />
31 mph None<br />
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w w w . a u t o s t e e l . o r g<br />
Outline<br />
• Introduction – Generic Cross-section<br />
• <strong>DP600</strong> Multicorner Columns in Axial Crush<br />
• <strong>DP600</strong> Multicorner Columns in Side Bending<br />
• <strong>DP600</strong> 12 Corner Columns in Full Vehicle<br />
<strong>Front</strong>al <strong>Impact</strong> Application<br />
• Conclusions
C1<br />
Cross-section<br />
C0<br />
Cross-section<br />
C2<br />
Cross-section<br />
w w w . a u t o s t e e l . o r g<br />
Tapered Cross-sections
C1<br />
Cross-section<br />
Tapered Cross-sections with Convolutions<br />
C0<br />
Cross-section<br />
C2<br />
Cross-section<br />
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Sensitivity Analyses (Tapered Crosssections<br />
with Convolutions - C1)<br />
Best-fit (2.3mm)<br />
Baseline<br />
w w w . a u t o s t e e l . o r g<br />
C1<br />
DOE Setup<br />
Material - <strong>DP600</strong><br />
Gage=3.3 ~ 2.1 mm<br />
Best-Fit<br />
C1 –<strong>DP600</strong>–2.3mm<br />
Weight x2 = 18.87 lb<br />
Saving = 8.25 lb<br />
(30.42%)
Best-fit (2.3mm)<br />
Sensitivity Analyses (Tapered Crosssections<br />
with Convolutions- C2)<br />
Baseline<br />
w w w . a u t o s t e e l . o r g<br />
C2<br />
DOE Setup<br />
Material – P415 AP1<br />
Gage=3.3 ~ 2.1 mm<br />
Best-Fit<br />
C2 –AP1_mat–2.3mm<br />
Weight x2 = 18.21 lb<br />
Saving = 8.91 lb<br />
(32.86%)
<strong>Front</strong> Rail Design<br />
Material<br />
32Ksi<br />
<strong>DP600</strong><br />
Tapered Cross Section<br />
Without Convolution<br />
w w w . a u t o s t e e l . o r g<br />
Tapered Cross Section<br />
With Convolution<br />
C0 C1 C2 C0 C1 C2<br />
Gage (mm) 3.30 2.70 2.10 3.30 2.70 2.30<br />
Weight (lb) 24.95 20.69 16.06 27.12 21.69 18.21<br />
Saving<br />
(lb) 0.00 4.26 8.89 0.00 5.43 8.91<br />
(%) 0.00 17.09 35.64 0.00 20.01 32.86<br />
Gage (mm) 2.90 2.30 1.70 2.70 2.30 2.00<br />
Weight (lb) 21.91 19.18 13.01 22.18 18.87 15.83<br />
Saving<br />
Component Performance Comparison<br />
(lb) 3.04 5.77 11.94 4.94 8.25 11.29<br />
(%) 12.18 23.13 47.87 18.22 30.42 41.64
Full Vehicle Crash Application<br />
Baseline 12-Corner<br />
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Baseline<br />
12-Corner<br />
NCAP Performance Comparison<br />
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Baseline<br />
12-Corner<br />
NCAP Deformation Comparison<br />
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Baseline<br />
12-Corner<br />
IIHS Offset Performance Comparison<br />
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IIHS Offset Intrusion Comparison<br />
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Outline<br />
• Introduction – Generic Cross-section<br />
• <strong>DP600</strong> Multicorner Columns in Axial Crush<br />
• <strong>DP600</strong> Multicorner Columns in Side Bending<br />
• <strong>DP600</strong> 12 Corner Columns in Full Vehicle<br />
<strong>Front</strong>al <strong>Impact</strong> Application<br />
• Conclusions
w w w . a u t o s t e e l . o r g<br />
Conclusions<br />
• Geometry, material properties, forming effect, welding<br />
effect, strain rate, <strong>and</strong> other boundary conditions all<br />
contribute to model correlation <strong>and</strong> prediction.<br />
• The octagon has a small advantage over hexagon with<br />
respect to energy absorption in axial crush <strong>and</strong> lateral<br />
bending.<br />
• The 12 corner cross section presents more advantage over<br />
the other sections studied.<br />
• The 12 corner cross section saves weight <strong>and</strong> performs<br />
slightly better than the baseline design in front impact crash<br />
performances.
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