FT09 AME510

M.S RAMAIAH SCHOOL OF ADVANCED STUDIES

Postgraduate Engineering and Management Programme [PEMP]

Department: Automotive Design and Engineering

Course: Automotive Engineering/Automotive Product Design
Module Code: AME510
Module Title: Structures, Safety and Impact
Module Leader: Vinod Banthia, R. Lalith Kumar, Pradeep, P.P.

Assignment

INSTRUCTIONS TO CANDIDATES:

1. This assignment has three parts

2. The weightage of the three parts are – Part A (20), Part B (35) and Part C (45)
3. The assignment should be word processed confirming to the format prescribed in the template
provided by the ARO
4. The length of the assignment report should be limited to 35 pages.
5. The assignment should be submitted to the ARO’s office on or before 04-Sep-10
6. LS-Dyna and MADYMO should be used for the simulation based problems
7. All the units of measurement wherever applicable should be SI Units only
8. The scheme and assessment of the assignment will be as specified in the statement of the
assignment problem and Guidelines for submission.
9. Group discussion is permitted but the simulation, interpretation of the results, conclusions and
report should be individual effort
10. IMPORTANT: It essential that all the sources used in preparation of the assignment must be
suitably referenced in the text.

<August 2010>

Form – 43 Ver: 2 Date: 01-08-2009 1

FT09 AME510

Introduction:

The speed differential, between moving vehicles and pedestrians, or decelerating

vehicle and its occupants, is the source of injuries to the humans involved in an automotive
collision. Understanding of this phenomenon is critical for designing of exterior and interior
structural and trim components to minimize the injury to human beings involved. Extensive
deformation of complex structure and behaviour of human body to impact loading make it
difficult to analyze these phenomena.
Because of this, testing and numerical simulations play an important role in recreating
the scenario for understanding. Two such simulation packages, MADYMO and LS-Dyna
have reached a level where they can mimic the real world behaviour of the structure and
human beings in collision. The two problems in this assignment will provide the students an
opportunity to use these tools for simulation of scenarios that are similar in nature to real life
collision of vehicles and humans.

Problem statement and Guidelines for Submission

Part A
Initiation of Golden Quadrilateral project has spurred the development of multi-lane world
class highways connecting major cities in India. The goal of this project is to facilitate high
speed road travel which was not possible with the existing infrastructure. Even partial
development of the network roads has demonstrated the tremendous impact it will have on
road transport in the future. Even now, with only about 2% of Indian road network under
GQ, it carries about 40% of total road traffic. Unfortunately, it also accounts for about 35%
of road fatalities [1].
This has given rise to a dichotomy as the network for “high speed” road transport is lined
with bill-boards screaming “Speed Kills” and dotted with speed bumps and barriers. In the
opinion of some this beats the purpose of the network.
Based on this background, debate the statement “To limit the fatalities on roads, travel speed
should be kept low even on the Golden Quadrilateral and other road network being built
for faster road transport.” Limit your reasons, arguments, justifications and conclusion to
three A4 pages. Include some discussion on the Physics involved in this problem to explain
your reasons. Limit this discussion on Physics to a maximum of one-fourth of the total
presentation.
(05+10+05) marks
Part B
In an automobile, side impact accident places the driver and occupants of a vehicle at higher
risk than other types of accidents. Hence, for an adequate design of the door system, understanding
the performance of its components under impact
loading, like the one expected in a collision, is of great
importance. Simulations of transient dynamic
phenomena in which the components undergo
non-linear deformation provide designer a tool to assess
different design alternatives and their effect on the
crashworthiness of the automobile.

In this problem, side pole impact test on the given

design of the outer panel of a door assembly is to be

Form – 43 Ver: 2 Date: 01-08-2009 2

 FT09 AME510

carried out. The aim of this assignment is to study the non-linear behavior of the door components
(Fig.2) under Pole Test Fixture loading

i) For the given Hypermesh model and material data (tabulated below) for door
assembly, carry out simulation of impact of the door on to a moving Pole Test
Fixture at a velocity of 29 km/h. Assume that the Pole Test Fixture comes and
impacts at the center of the door assembly. 5 Marks
ii) From Figure 1 we can see that intrusion level in the door assembly is very high
which ricks the safety of the passengers, suggest a suitable design change to avoid
such situation. Implement suggested design change in the model and carry out the
simulation again to demonstrate the effectiveness of the proposed design. Explain
the simulation model and results in a viva to be held in the lab 5+7Marks
iii) Obtain the resultant contact forces, acceleration, deformation and energy plots and
comment on the results for the above mentioned cases. 8 Marks
iv) Review and discuss the behavior of the door assembly during pole impact and
compare the results for the above two cases (i.e. between existing design and
proposed design). Also, identify and compare the nature and extent of damage in
the door parts. 10 Marks
Dimensions used for creating a side pole are as shown below.
Pole Diameter = 200 mm
Pole Length = 2000 mm

Part Name Thickness Density Young’s Poisson’s Yield Strain rate Strain rate
(mm) (t/mm3) Modulus Ratio stress parameter parameter
(GPa) (MPa) (C) (P)
Door Front 1.04 7.89e-09 210 0.3 200 8000 8.0
Interior Bar
(stiffener) 2.5 7.89e-09 210 0.3 480 8000 8.0
Bar bracket 2.1 7.89e-09 210 0.3 370 8000 8.0
Door left front
window
1.7 7.89e-09 210 0.3 300 8000 8.0
Front window motor 3.0 9.10e-10 2800 0.3 45 ----- -----
Door left front
window motor 2.44e-09 210 0.3
Door front hinge 4.9 7.89e-09 210 0.3 480 8000 8.0

Form – 43 Ver: 2 Date: 01-08-2009 3

 FT09 AME510

Glass 3.9 2.5e-09 76 0.3

Material properties in the non-linear range

1. Door front
Effective plastic strain 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13
Yield stress (MPa) 200 205 209 211 215 218 221 224 228 232 236 239 241 244

2. Interior bar (stiffeners)

Effective plastic strain 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13
Yield stress (MPa) 480 481 514 530 539 552 563 574 584 593 602 609 617 624

3. Interior bar brackets

Effective plastic strain 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13
Yield stress (MPa) 370 391 424 436 448 464 478 491 504 515 526 536 545 554

4. Door left front window bracket

Effective plastic strain 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13
Yield stress (MPa) 300 314 323 330 337 343 349 355 360 365 370 374 380 383

5. Door front window motor

Effective plastic strain 0 0.03 0.08 0.17 0.25 0.32 0.36 0.39 1.0
Yield stress (MPa) 45 54 61 68 76 85 93 108 200

6. Door front hinge

Effective plastic strain 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13
Yield stress (MPa) 480 481 514 530 539 552 563 574 584 593 602 609 617 624

Part C
A two-wheeler hitting a median or a barrier is a common accident scenario in crowded
Indian cities. The resulting injury to the rider depends on the motion of the vehicle and that
of the rider after impact. That, in
turn, depends on the size and shape
of the barrier and the velocity of the
bike. Hence, injury to the rider can
be brought down by changing the
shape of the barrier. The assigned
problem is aimed at understanding
this effect of barrier design on the
resulting injuries to the rider.
Outcome of the problems solved by
the students will provide an insight
into the effect on rider injury of
barrier design (maximum height

Form – 43 Ver: 2 Date: 01-08-2009 4

FT09 AME510

0.5 m), speed and mass of the vehicle and angle of approach.

For the prescribed set of data from Table 1

i) Model the environment (two-wheeler, barrier, road and Hybrid ΙΙΙ 50th percentile dummy
in riding posture) 5 marks
ii) Carry out simulation of two-wheeler impacting the barrier of the basic design (Figure 5)
at 30 km/h to 70 km/h in steps of 10 km/h. Comment on the rider kinematics and record
HIC value, tibia acceleration, femur acceleration and neck acceleration of the rider.
Explain the simulation model and results in a viva to be held in the lab. (8+7) marks
iii) Come up with three new different barrier designs with an aim to reduce rider injury for
50 km/h speed. Comment on the rider kinematics and effectiveness of the design changes
in reducing rider injury. Using the trends of the results suggest further changes for
improving the design. 3*5 marks
iv) Comment on how the assignment problems relate to and help achieve the Learning Outcomes
(listed below) for the module.
Format your report as per the prescribed template and instructions.

Learning objectives for AME510

1. Identify and quantify the loads, and their characteristics, for the design of automotive structures
as per standards
2. Design and analyse automotive structures for strength, durability and safety
3. Analyse a collision phenomena and its effects
4. Use LS-Dyna and MADYMO for modelling and simulation of crash and collision
Guidelines for submission
• Results of the 50 km/h impact only should be presented along with the images. Results
from all other speeds should be tabulated.
• The model files (.XML files) are to be submitted to the module leader on a prescribed
day and time. Naming and organization of files should be as explained in the class.
References
1. Christy Ulrich, “India’s Golden Quadrilateral,”, National Geographic, September 15, 2008,
http://ngm.nationalgeographic.com/geopedia/India_Highway, Accessed on 01-Aug-10.

Table 1 Detail for the Simulation

Students Reg. Impact Bike Students Reg. Impact Bike
 
No. angles model No. angles model
BYB0909001 20   BYB0909025 35
Bajaj
BYB0909002 25   BYB0909026 40
Avenger
BYB0909003 30 Hero   BYB0909027 45 220
BYB0909004 35 Honda   BYB0909028 90
BYB0909005 40 Karizma   BYB0909029 20
BYB0909006 45   BYB0909030 25
BYB0909007 90   BBB0909001 30 Royal
BYB0909008 20   BBB0909002 35 Enfield
BYB0909009 25 Bajaj   BBB0909003 40 Bullet 350
BYB0909010 30 Pulsar 180   BBB0909004 45
BYB0909011 35   BBB0909005 90

Form – 43 Ver: 2 Date: 01-08-2009 5

FT09 AME510

Students Reg. Impact Bike Students Reg. Impact Bike

 
No. angles model No. angles model
BYB0909012 40   BBB0909006 20
BYB0909013 45   BBB0909007 25
BYB0909014 90   BBB0909008 30
Yamaha
BYB0909015 20   BBB0909009 35 FZ
BYB0909016 25   BBB0909010 40
BYB0909017 30 TVS   BBB0909011 45
BYB0909018 35 Apache   BBB0909012 90
BYB0909019 40 RTR 160   BBB0909013 20
BYB0909020 45   BBB0909014 25
BYB0909021 90   BBB0909015 30 Honda
BYB0909022 20 Bajaj   BBB0909016 35 Unicorn
BYB0909023 25 Avenger   BBB0909017 40
BYB0909024 30 220   BBB0909018 45

Marking Scheme
Section Description Marks
A1. Arguments 5
A2. Organisation 10
A3. Presentation 5
Total (Part A) 20
B1. Modeling and simulation 5
B2. Implementing proposed design and carrying out simulation + Viva 5+7
B3. Post-processing 8
B4. Comparing and interpretation of the results between existing 10
design and proposed design and compare the nature and extent of
damage in the door parts
Total (Part B) 35
C1. Environment modeling 5
C2. Basic Design simulation and result interpretation + Viva 8+7
C3. Modified barrier design simulation and comment on the 15
effectiveness of design changes and trends
C4. Comments on Learning Outcomes and Formatting 5+5
Total (Part C) 45

Form – 43 Ver: 2 Date: 01-08-2009 6