Evaluating Crashworthiness of Various Frontal Car Body Materials and Designs by Performing the Frontal Crash Test Using FEA Simulation
DOI:
https://doi.org/10.26821/IJSHRE.12.12.2024.121206Keywords:
Car body crash test, FEA simulation, 3D designAbstract
This study evaluates the crashworthiness of various frontal car body designs and materials through Finite Element Analysis (FEA) simulation to optimize passenger safety, weight, and structural integrity. Three frontal chassis designs - tubular, rectangular, and modular - were modeled in SolidWorks and subjected to a frontal crash force of 30G (gravity force) using the ANSYS FEA module. Each chassis was tested with three materials: stainless steel (SS), aluminum alloy (6061 T6), and carbon fiber (CF). Results indicated that the modular frame with stainless steel exhibited the least deformation (0.174 mm) and the highest stress capacity (196.58 MPa), making it ideal for safety-critical applications. Aluminum alloy emerged as a balanced choice with deformation values ranging from 0.505 mm to 13.573 mm, offering a trade-off between weight reduction and crashworthiness. Carbon fiber, despite its lightweight properties, showed significant deformation in the rectangular frame design (137.49 mm), highlighting the need for reinforcement in high-impact scenarios. Among the chassis types, the tubular frame paired with stainless steel provided the best strength-to-weight ratio. In contrast, the modular frame with aluminum alloy was deemed suitable for weight-sensitive environments. This research underscores the importance of material and design selection in enhancing vehicle safety and performance. The findings have significant implications for the automotive industry, enabling optimized design approaches to meet stringent safety regulations while improving fuel efficiency.
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