Modeling, Simulation and Prediction of Vehicle Crashworthiness in Full Frontal Impact

Abstract

Vehicle crashworthiness assessment is critical to help reduce road accident fatalities and ensure safer vehicles for road users. Techniques to assess crashworthiness include physical tests and mathematical modeling and simulation of crash events, the latter is preferred as mathematical modeling is generally cheaper to perform in comparison with physical testing. The most common mathematical modeling technique used for crashworthiness assessment is nonlinear Finite Element (FE) modeling. However, a problem with the use of Finite Element Model (FEM) for crashworthiness assessment is inaccessibility to individual researchers, public bodies, small universities and engineering companies due to need for detailed CAD data, software licence costs along with high computational demands. This thesis investigates modeling strategies which are affordable, computationally and labour inexpensive, and could be used by the above-mentioned groups. Use of Lumped Parameter Models (LPM) capable of capturing vehicle parameters contributing to vehicle crashworthiness has been proposed as an alternative to adopting FEM, while the later have been used to validate LPMs developed in this thesis. The main crash scenario analysed is a full frontal impact against a rigid barrier. Front-end deformation which can be used to measure crash energy absorption and pitching which could lead to occupant injuries in a frontal crash event are parameters focused on. The thesis investigates two types of vehicles; vehicle with initial structure intact is defined as baseline vehicle, while a vehicle that underwent unprofessional repairs on its structural members made of Ultra High Strength Steel (UHSS) is defined as a modified vehicle. The proposed novel LPM for a baseline vehicle impact is inspired by pendulum motion and expresses the system using Lagrangian formulation to predict the two phases of impact: front-end deformation and vehicle pitching. Changes in crashworthiness performance of a modified vehicle were investigated with a FEM; tensile tests on UHSS coupons were conducted to generate material inputs for this FEM. Further, a full scale crash test was conducted to validate the FE simulations. An LPM to conduct crashworthiness assessment of a modified vehicle has been proposed, it is based on a double pendulum with a torsional spring representing the vehicle undergoing a full frontal impact.