Finite Element Modelling of the Frame for Body-On-Frame Vehicles: Part Ii - Full Vehicle Crash

Document Number: 2004-01-0689

Date Published: March 2004

Author(s):
Yijung Chen - Ford Motor Co.
Ryan Craig - Ford Motor Co.
Tau Tyan - Ford Motor Co.
Jeffrey Laya - Ford Motor Co.
James C. Cheng - Ford Motor Co.

Abstract:
This study focuses on the modelling of a frame in a body-on-frame (BOF) vehicle to improve the prediction of vehicle response in crashes. The study is divided into three phases - component (frame material modelling), subsystem (frame sled test) and full system (full-vehicle test). In the component level, we investigate the available strain rate data, the performance of various material models in crash codes and the effect of the strain rate in crash simulation. In the subsystem phase, we incorporate the strain rate modelling and expand the scope to include both the forming and the welding effects in the subsystem CAE model to improve the correlation between CAE and test. Finally the improved frame modelling methodology with strain rate, forming and welding effects is adopted in full-vehicle model. It is found that the proposed frame modelling methodology is crucial to improve the pulse prediction of a full vehicle in crashes. The details of the component and subsystem studies are provided in a separate paper. This paper only discusses the correlation between full-vehicle crash tests and the corresponding CAE simulations. The full-vehicle crash tests are conducted at different conditions including crash modes, crash speeds, drive configurations and vehicle weights. The CAE results with respect to each test condition are compared with the data recorded in physical test. With the proposed frame modelling methodology, it is possible to use one single CAE model to correlate with all different test conditions.

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Product Status: In Stock

See other papers presented at SAE 2004 World Congress & Exhibition, March 2004, Detroit, MI, USA, Session: Modeling of Materials for Crash Applications (Part 2 of 2)

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