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Multiple experimental studies were performed on galling intiation for variety of tooling materials, coatings and surface treatments, sheet materials with various surface textures and lubrication. Majority of studies were performed for small number of samples in laboratory conditions. In this paper, the methodology of screening experiment using different combinations of tooling configurations and sheet material in the lab followed by the high volume small scale U-bend performed in the progressive die on the mechanical press is discussed. The experimental study was performed to understand the effect of the interface between the sheet metal and the die surface on sheet metal flow during stamping operations. Aluminum sheet AA5754 2.5mm thick was used in this experimentation. The sheet was tested in laboratory conditions by pulling between two flat insert with controllable clamping force and through the drawbead system with variable radii of the female bead.

The application of optical diagnostics in turbulent reactive flows often suffers from the beam steering (BS) effects, resulting in degraded image quality and/or measurement accuracy. This work investigated a method to correct the BS effects to improve the accuracy of optical diagnostics, with particle imagine velocimetry (PIV) measurements on turbulent reactive flames as an example. The proposed method used a guiding laser to correct BS. Demonstration in laboratory turbulent flames showed promising results where the accuracy of PIV measurement was significantly enhanced. Applicability to more complicated and practical situations are discussed.

Females have higher frequency and risk of foot and ankle injuries in motor vehicle collisions than similar-sized males. Therefore, lower extremity biofidelity and accurate injury prediction of female ATDs is critical. This paper aims to compare the THOR 5th percentile female (THOR-05F) anthropomorphic test device (ATD) response with male and female PMHS data of various sizes under ankle inversion and eversion. The THOR-05F lower extremity was subjected to dynamic inversion and eversion ankle loading with a constant 2000N axial force applied through the tibia. Twelve THOR-05F tests (3 inversion and 3 eversion on both, left and right legs) were performed with boundary conditions consistent with previous post-mortem human subject (PMHS) lower extremity tests.

This paper presents the development of a sensor suite that is used to measure the toeboard threedimensional (3D) dynamic deformation during a crash test, along with the methodology to use the sensor suite for toeboard measurement. The sensor suite consists of three high-speed cameras, which are firmly connected through a rigid metal frame. Two cameras, facing directly towards the toeboard, measure the shape of the toeboard through stereovision. The third camera, facing the ground, is equipped with a three-axis gyroscope and a three-axis accelerometer and localizes the sensor suite globally for removing the vibration of the sensor suite. The sensor suite was mounted onto the car through car seat mounting bolt holes, and a hole was made on the floor to let the downward camera see the ground. A pipeline using the data collected by the sensor suite is also introduced in this paper.

For developing complicated after-treatment equipment for diesel-engine vehicles, such as urea-selective catalytic reduction (urea-SCR) systems, construction of a reaction model that can accurately predict ammonia (NH3) formation from urea is required. Hydrolysis of isocyanic acid (HNCO) is an important intermediate reaction in NH3 formation from urea. In our previous studies [1], a new rate constant for HNCO hydrolysis over fresh Cu-ZSM5 was derived using the measurements of the reaction rate of HNCO hydrolysis with high-purity HNCO formed from cyanuric acid. In this study, the reaction rates of the HNCO hydrolysis and NH3-SCR reactions were measured over a hydrothermally aged Cu-ZSM5 catalyst. A steady-state flow reactor equipped with a Fourier transform infrared spectrometer (FTIR) was employed to obtain the reaction rate of the HNCO hydrolysis and NH3-SCR reactions.

Current state-of-the-art vehicles implement pedestrian protection features that rely on pedestrian detection sensors and algorithms to trigger when impacting a pedestrian. During the development phase, the vehicle must “learn” to discriminate pedestrians from the rest of potential impacting objects. Part of the training data used in this process is often obtained in physical tests utilizing legform impactors whose external biofidelity is still to be evaluated. This study uses THUMS as a reference to assess the external biofidelity of the most commonly used impactors (Flex-PLI, PDI-1 and PDI-2). This biofidelity assessment was performed by finite element simulation measuring the bumper beam forces exerted by each surrogate on a sedan and a SUV. The bumper beam was divided in 50 mm sections to capture the force distribution in both vehicles. This study, unlike most of the pedestrian-related literature, examines different impact locations and velocities.

Pedestrian finite element models (PFEM) are used to investigate and predict the injury outcomes from vehicle-pedestrian impact. As postmortem human surrogates (PMHS) differ in anthropometry across subjects, it is believed that the biofidelity of PFEM cannot be properly evaluated by comparing a generic anthropometry model against the specific PMHS test data. Global geometric personalization can scale the PFEM geometry to match the height and weight of a specific PMHS, while local geometric personalization via morphing can modify the PFEM geometry to match specific PMHS anatomy. The goal of the current study was to evaluate the benefit of morphed PFEM compared to globally-scaled and generic PFEM by comparing the kinematics against PMHS test results. The AM50 THUMS PFEM (v4.01) was used as a baseline for anthropometry, and personalized PFEM were created to the anthropometric specifications of two obese PMHS used in a previous pedestrian impact study using a mid-size sedan.

Some rollover testing methodologies require specification of vehicle kinematic parameters including travel speed, vertical velocity, roll rate, and pitch angle, etc. at the initiation of vehicle to ground contact, which have been referred to as touchdown conditions. The complexity of the vehicle, as well as environmental and driving input characteristics make prediction of realistic touchdown conditions for rollover crashes, and moreover, identification of parameter sensitivities of these characteristics, is difficult and expensive without simulation tools. The goal of this study was to study the sensitivity of driver input on touchdown parameters and the risk of rollover in cases of steering-induced soil-tripped rollovers, which are the most prevalent type of rollover crashes. Knowing the range and variation of touchdown parameters and their sensitivities would help in picking realistic parameters for simulating controlled rollover tests.

Multiple laboratory dynamic test methods have been developed to evaluate vehicle crashworthiness in rollover crashes. However, dynamic test methods remove some of the characteristics of actual crashes in order to control testing variables. These simplifications to the test make it difficult to compare laboratory tests to crashes. One dynamic method for evaluating vehicle rollover crashworthiness is the Dynamic Rollover Test System (DRoTS), which simulates translational motion with a moving road surface and constrains the vehicle roll axis to a fixed plane within the laboratory. In this study, five DRoTS vehicle tests were performed and compared to a pair of unconstrained steering-induced rollover tests. The kinematic state of the unconstrained vehicles at the initiation of vehicle-to-ground contact was determined using instrumentation and touchdown parameters were matched in the DRoTS tests.

While over 30% of US occupant fatalities occur in rollover crashes, no dummy has been developed for such a condition. Currently, an efficient, cost-effective methodology is being implemented to develop a biofidelic rollover dummy. Instead of designing a rollover dummy from scratch, this methodology identifies a baseline dummy and modifies it to improve its response in a rollover crash. Using computational models of the baseline dummy, including both multibody (MB) and finite element (FE) models, the dummy’s structure is continually modified until its response is aligned (using BioRank/CORA metric) with biofidelity targets. A previous study (Part I) identified the THOR dummy as a suitable baseline dummy by comparing the kinematic responses of six existing dummies with PMHS response corridors through laboratory rollover testing.

Recreational Off-Highway Vehicles (ROVs), since their introduction onto the market in the late-1990s, have been related to over 300 fatalities with the majority occurring in vehicle rollover. In recent years several organizations made attempts to improve ROV safety. This paper is intended to evaluate ejection mitigation measures considered by the ROV manufacturers. Evaluated countermeasures include two types of occupant restraints (three and four point) and two structural barriers (torso bar, door with net). The Rollover protection structure (ROPS) provided by the manufacturer was attached to a Dynamic Rollover Test System (DRoTS), and a full factorial series of roll/drop/catch tests was performed. The ROV buck was equipped with two Hybrid III dummies, a 5th percentile female and a 95th percentile male. Additionally, occupant and vehicle kinematics were recorded using optoelectronic stereophotogrammetric camera system.

To serve as tools for assessing injury risk, the biofidelity of whole-body pedestrian impact dummies should be validated against reference data from full-scale pedestrian impact tests. To facilitate such evaluations, a simplified generic vehicle-buck has been recently developed that is designed to have characteristics representative of a generic small sedan. Three 40 km/h pedestrian-impact tests have been performed, wherein Post Mortem Human Surrogates (PMHS) were struck laterally in a mid-gait stance by the buck. Corridors for select trajectory measures derived from these tests have been published previously. The goal of this study is to act as a companion dataset to that study, describing the head velocities, body region accelerations (head, spine, pelvis, lower extremities), angular velocities, and buck interaction forces, and injuries observed during those tests.

In recent years, there has been a growing desire to incorporate computational methods into aircraft icing certification practices. To improve understanding of ice shapes, a new experimental program in the NASA Icing Research Tunnel (IRT) will investigate swept hybrid models which are very large relative to the test section and are intended to operate at high lift coefficients. The present computations were conducted to help plan the experiments and to ascertain any effects of flow separation and unsteady forces. As they can be useful in robustly and accurately predicting large separation regions and capturing flow unsteadiness, a Detached Eddy Simulation (DES) approach has been adopted for simulating the flow over these large high-lift wing sections. The DES methodology was first validated using experimental data from an unswept NACA 0012 airfoil with leading-edge ice accretion, showing reasonable performance.

Multibody human models are widely used to investigate responses of human during an automotive crash. This study aimed to validate a commercially available multibody human body model against response corridors from volunteer tests conducted by Naval BioDynamics Laboratory (NBDL). The neck model consisted of seven vertebral bodies, and two adjacent bodies were connected by three orthogonal linear springs and dampers and three orthogonal rotational springs and dampers. The stiffness and damping characteristics were scaled up or down to improve the biofidelity of the neck model against NBDL volunteer test data because those characteristics were encrypted due to confidentiality. First, sensitivity analysis was performed to find influential scaling factors among the entire set using a design of experiment.

A follow-up case study on rollover testing with a single full-size sport utility vehicle (SUV) was conducted under controlled real-world conditions. The purpose of this study was to conduct a well-documented rollover event that could be utilized in evaluating various methods and techniques over the phases associated with rollover accidents. The phases documented and discussed, inherent to rollovers, are: pre-trip, trip, and rolling phases. With recent advances in technology, new devices and techniques have been designed which improve the ability to capture and document the unpredictable dynamic events surrounding vehicle rollovers. One such device is an inertial measurement unit (IMU), which utilizes GPS technology along with integrated sensors to report and record measured dynamic parameters real-time. The data obtained from a RT-4003 IMU device are presented and compared along with previous test data and methodology.

Occupant kinematics during rollover motor vehicle collisions have been investigated over the past thirty years utilizing Anthropomorphic Test Devices (ATDs) in various test methodologies such as dolly rollover tests, CRIS testing, spin-fixture testing, and ramp-induced rollovers. Recent testing has utilized steer maneuver-induced furrow tripped rollovers to gain further understanding of vehicle kinematics, including the vehicle's pre-trip motion. The current study consisted of two rollover tests utilizing instrumented test vehicles and instrumented ATDs to investigate occupant kinematics and injury response throughout the entire rollover sequences, from pre-trip vehicle motion to the position of rest. The two steer maneuver-induced furrow tripped rollover tests utilized a mid-sized 4-door sedan and a full-sized crew-cab pickup truck. The pickup truck was equipped with seatbelt pretensioners and rollover-activated side curtain airbags (RSCAs).

The objective of the study was to analyze independently the contribution of pre-impact spine posture on impact response by subjecting a finite element human body model (HBM) to whole-body, lateral impacts. Seven postured models were created from the original HBM: one matching the standard driving posture and six matching pre-impact posture measured for each of six subjects tested in previously published experiments. The same measurements as those obtained during the experiments were calculated from the simulations, and biofidelity metrics based on signals correlation were established to compare the response of HBM to that of the cadavers. HBM responses showed good correlation with the subject response for the reaction forces, the rib strain (correlation score=0.8) and the overall kinematics. The pre-impact posture was found to greatly alter the reaction forces, deflections and the strain time histories mainly in terms of time delay.

Rollover crashes are a serious public health problem in United States, with one third of traffic fatalities occurring in crashes where rollover occurred. While it has been shown that occupant kinematics affect the injury risk in rollover crashes, no anthropomorphic test device (ATD) has yet demonstrated kinematic biofidelity in rollover crashes. Therefore, the primary goal of this study was to assess the kinematic response biofidelity of six ATDs (Hybrid III, Hybrid III Pedestrian, Hybrid III with Pedestrian Pelvis, WorldSID, Polar II and THOR) by comparing them to post mortem human surrogate (PMHS) kinematic response targets published concurrently; and the secondary goal was to evaluate and compare the kinematic response differences among these ATDs.

Some rollover test methods, which impose a touchdown condition on a test vehicle, have been developed to study vehicle crashworthiness and occupant protection in rollover crashes. In ground-tripped rollover crashes, speed, steering maneuver, braking, vehicle inertial and geometric properties, topographical and road design characteristics, and soil type can all affect vehicle touchdown conditions. It is presumed that while there may be numerous possible combinations of kinematic metrics (velocity components and orientation) at touchdown, there are also numerous combinations of metrics that are not likely to occur in rollover crashes. To determine a realistic set of touchdown conditions to be used in a vehicle rollover crash test, a lateral deceleration sled-based non-destructive rollover initiation test system (RITS) with a fully programmable deceleration pulse is in development.

The goal of this study was to evaluate the biofidelity of the three computational surrogates (GHBMC model, WorldSID model, and the FTSS ES-2re model) under the side impact rigid wall sled test condition. The responses of the three computational surrogates were compared to those of post mortem human surrogate (PMHS) and objectively evaluated using the correlation and analysis (CORA) rating method. Among the three computational surrogates, the GHBMC model showed the best biofidelity based on the CORA rating score (GHBMC =0.65, WorldSID =0.57, FTSS ES-2re =0.58). In general, the response of the pelvis of all the models showed a good correlation with the PMHS response, while the response of the shoulder and the lower extremity did not. In terms of fracture prediction, the GHBMC model overestimated bone fracture.