Estimating Local Part Thickness in Midplane Meshes for Finite Element Analysis

Within the development of motor vehicles, crash safety (e.g. occupant protection, pedestrian protection, low speed damageability), is one of the most important attributes. In order to be able to fulfill the increased requirements in the framework of shorter cycle times and rising pressure to reduce costs, car manufacturers keep intensifying the use of virtual development tools such as those in the domain of Computer Aided Engineering (CAE). For crash simulations, the explicit finite element method (FEM) is applied. The accuracy of the simulation process is highly dependent on the accuracy of the simulation model, including the midplane mesh. One of the roughest approximations typically made is the actual part thickness which, in reality, can vary locally. However, almost always a constant thickness value is defined throughout the entire part due to complexity reasons. On the other hand, for precise fracture analysis within FEM, the correct thickness consideration is one key enabler. Thus, availability of per element thickness information, which does not exist explicitly in the FEM model, can significantly contribute to an improved crash simulation quality, especially regarding fracture prediction. Even though the thickness is not explicitly available from the FEM model, it can be inferred from the original CAD geometric model through geometric calculations. This paper proposes and compares two thickness estimation algorithms based on ray tracing and nearest neighbour 3D range searches. A systematic quantitative analysis of the accuracy of both algorithms is presented, as well as a thorough identification of particular geometric arrangements under which their accuracy can be compared. These results enable the identification of each technique’s weaknesses and hint towards a new, integrated, approach to the problem that linearly combines the estimates produced by each algorithm.

Törmäysystävällisen valaisinpylvään tuotteistaminen

Euroopan unioni on tiukentanut teiden laitteiden ja tukirakenteiden törmäysturvallisuusvaatimuksia. Uuden standardoinnin tarkoituksena on lieventää ajoneuvon kuljettajan ja matkustajan vammojen vakavuutta ajoneuvon törmätessä tielaitteiden pysyviin rakenteisiin. Käytännössä rakenteiden tulee hidastaa ajoneuvon nopeutta hallitusti eri törmäysnopeuksilla, jolloin matkustajaan kohdistuvat kiihtyvyydet eivät aiheuta vakavaa loukkaantumisriskiä. Vuonna 2005 Mikkelin ammattikorkeakoulun YTI-tutkimuskeskus ja Tehomet Oy kehittivät ensimmäisen version törmäysystävällisestä valaisinpylväästä. Tässä diplomityössä tavoitteena oli kehittää aikaisemmin tehdystä versiosta helpommin valmistettava versio sekä parantaa pylvään törmäyskäyttäytymistä. Valmistusmenetelmistä valittiin pultruusio, kuitukelaus, alipaineinjektio ja RTM. Menetelmille suunniteltiin soveltuvat rakenteet ja laskettiin rakenteiden valmistuskustannukset. Pultruusiolla, alipaineinjektiolla ja RTM:11ä valmistettiin koe-erä esitörmäyskokeita varten. Esitörmäyskokeiden jälkeen valittiin valmistusmenetelmäksi RTM. TKK/Tielaboratorion virallisissa testeissä kehitetylle pylväälle myönnettiin HE2-turvaluokitus. Hanketta jatketaan kehittämällä valmistusprosessia tehokkaammaksi uudistamalla muottitekniikkaa sekä ottamalla käyttöön lujiteaihiot. Tavoitteena on käynnistää tuotanto keväällä 2008. Kehitetty pylväs esitellään kansainvälisillä "Sähkö, Tele, Valo- ja AV 2008"-messuilla Jyväskylän Paviljongissa 6.-8.2.2008.

Calibration of Highway Safety Manual Work Zone Crash Modification Factors, TPF-5(081), 2014

The Highway Safety Manual is the national safety manual that provides quantitative methods for analyzing highway safety. The HSM presents crash modification factors related to work zone characteristics such as work zone duration and length. These crash modification factors were based on high-impact work zones in California. Therefore there was a need to use work zone and safety data from the Midwest to calibrate these crash modification factors for use in the Midwest. Almost 11,000 Missouri freeway work zones were analyzed to derive a representative and stratified sample of 162 work zones. The 162 work zones was more than four times the number of work zones used in the HSM. This dataset was used for modeling and testing crash modification factors applicable to the Midwest. The dataset contained work zones ranging from 0.76 mile to 9.24 miles and with durations from 16 days to 590 days. A combined fatal/injury/non-injury model produced a R2 fit of 0.9079 and a prediction slope of 0.963. The resulting crash modification factors of 1.01 for duration and 0.58 for length were smaller than the values in the HSM. Two practical application examples illustrate the use of the crash modification factors for comparing alternate work zone setups.

Rail-highway crossing safety fatal crash and demographic descriptors.

National Highway Traffic Safety Administration, Office of Research and Development, Washington, D.C.

Minicars Research Safety Vehicle to 1979 Dodge Challenger crash test report - frontal aligned impact at 86.52 mph closing speed.

National Highway Traffic Safety Administration, Office of Vehicle Safety Compliance, Washington, D.C.

Research safety vehicle (RSV) crash test report: test no. 3054-1 - 41 mph flat barrier frontal impact. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Statistical evaluation of the effectiveness of Federal Motor Vehicle Safety Standard 222: School Bus Seating and Crash Protection. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Highway safety: reliability and validity of DOT crash tests.

Mode of access: Internet.

Report to Congress: benefits of safety belts and motorcycle helmets. Based on data from the Crash Outcome Data Evaluation System (CODES).

Mode of access: Internet.

Delineation of concrete safety-shaped barriers and urban freeway gore area crash cushions. Final report.

Texas State Department of Highways and Public Transportation, Transportation Planning Division, Austin

Evaluation methodologies for four federal motor vehicle safety standards. FMVSS 214: side door strength. FMVSS 301: fuel system integrity. FMVSS 215: exterior protection. FMVSS 208: occupant crash protection. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Crash testing of experimental safety vehicles. Volume I - British Leyland Marina Safety Research Vehicle. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Crash test of cone truck for operator safety. Final report.

Mode of access: Internet.

Evaluation plan for Federal Motor Vehicle Safety Standard 208 occupant crash protection.

Mode of access: Internet.

Traffic safety facts 1995 - a compilation of motor vehicle crash data from the Fatal Accident Reporting System and the General Estimates System.

Mode of access: Internet.