Crashworthiness Study of Lightweight Aluminum Automotive Structures


Project Schedule



The project is organized as a two year, phased effort:

  • Phase I (Year I)
    • Select an existing representative aluminum intensive vehicle.
    • Procure the selected vehicle.
    • Develop a geometric representation of the vehicle.
      • Scan the vehicle geometry using coordinate measurement devices.
      • Develop a three-dimensional representation of the scanned geometry.
    • Develop detailed computational models of the vehicle for crashworthiness studies
      • Create finite element model of the vehicle using the scanned geometry.
      • Develop a modeling environment that will allow for easy generation of vehicle models for different loading conditions. (e.g. front, offset, oblique, side impact with different obstacles and vehicles)
    • Develop computer environment that will allow for easy design modifications and material crashworthiness evaluations.
    • Perform basic model verification.


  • Phase II (Year II)
    • Perform computational simulations of collisions of the developed model for the aluminum intensive vehicle and various obstacles and vehicles.
    • Experimentally test the aluminum intensive vehicle crash performance (if data can not be obtained otherwise).
    • Verify the accuracy of the model against the experimental data.
    • Perform model modifications.
    • Quantify advantages of aluminum autobodies for crash situations.
  • Document the developments and findings.


Scope


The scope of the project is to accelerate the development and introduction of aluminum intensive auto bodies through the use of advanced computational simulations for the assessment of integrated design and performance. The project will:
1. Analyze the existing aluminum vehicle designs

  • analyze applicability of aluminum for different vehicle classes
  • Computational analysis of various collision situations with rigid and deformable barriers, and with characteristic current US fleet vehicles

2. Analyze the vehicle models representing the current US car fleet

  • Develop crashworthiness computer models
  • determine weight reduction potential using aluminum
  • perform design modifications required for aluminum
  • develop substructure design modification for aluminum
  • perform crashworthiness analysis of the modified design
  • evaluate aluminum advantages for different vehicle classes


3. Document the developments and findings.

This project takes advantage of ongoing vehicle crashworthiness projects at ORNL aimed at developing vehicle models that are representative of US car and truck fleet. These models are used as starting platforms for this project and only the activities specific to this project are performed.