Design of a New Vehicle Front End Structure to Optimise Crashworthiness

Mohab Elmarakbi; Madeleine Combrinck; Ahmed Elmasry; Ahmed Elmarakbi

doi:10.1115/imece2022-95911

Design of a New Vehicle Front End Structure to Optimise Crashworthiness

Mohab Elmarakbi, Madeleine Combrinck, Ahmed Elmasry, Ahmed Elmarakbi

Mechanical and Construction Engineering Department

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

Within this paper methods in reducing weight and optimizing the front-end structure, by specifically targeting both new materials and redesigning the cashbox, to improve crashworthiness were investigated. This was accomplished through redesigning the cross-sectional shape of the crash box, trigger location and type of trigger used, and the use of different materials. The optimal crash box design was found to be a hexagonal prism that incorporated a central trigger which reduced the thickness from 2mm to 1mm. Moreover, the ideal material was identified to be SGF/PA6/GnPls. When this optimized crash box was incorporated to the front-end structure and the ideal material applied to the bumper beam, the fully optimized front-end structure reduced the weight by 75%, reduced peak force by 28% and increased specific energy absorption by 94% and 55% for a frontal and side collision respectively.

Original language	English
Title of host publication	Proceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022.
Publisher	American Society of Mechanical Engineers (ASME)
Pages	1-11
Number of pages	11
ISBN (Electronic)	9780791886717
DOIs	https://doi.org/10.1115/imece2022-95911
Publication status	Published - 30 Oct 2022

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Elmarakbi, M., Combrinck, M., Elmasry, A., & Elmarakbi, A. (2022). Design of a New Vehicle Front End Structure to Optimise Crashworthiness. In Proceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022. (pp. 1-11). Article V009T14A006 American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/imece2022-95911

Elmarakbi, Mohab ; Combrinck, Madeleine ; Elmasry, Ahmed et al. / Design of a New Vehicle Front End Structure to Optimise Crashworthiness. Proceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022.. American Society of Mechanical Engineers (ASME), 2022. pp. 1-11

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abstract = "Within this paper methods in reducing weight and optimizing the front-end structure, by specifically targeting both new materials and redesigning the cashbox, to improve crashworthiness were investigated. This was accomplished through redesigning the cross-sectional shape of the crash box, trigger location and type of trigger used, and the use of different materials. The optimal crash box design was found to be a hexagonal prism that incorporated a central trigger which reduced the thickness from 2mm to 1mm. Moreover, the ideal material was identified to be SGF/PA6/GnPls. When this optimized crash box was incorporated to the front-end structure and the ideal material applied to the bumper beam, the fully optimized front-end structure reduced the weight by 75%, reduced peak force by 28% and increased specific energy absorption by 94% and 55% for a frontal and side collision respectively.",

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Elmarakbi, M, Combrinck, M, Elmasry, A & Elmarakbi, A 2022, Design of a New Vehicle Front End Structure to Optimise Crashworthiness. in Proceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022.., V009T14A006, American Society of Mechanical Engineers (ASME), pp. 1-11. https://doi.org/10.1115/imece2022-95911

Design of a New Vehicle Front End Structure to Optimise Crashworthiness. / Elmarakbi, Mohab; Combrinck, Madeleine; Elmasry, Ahmed et al.
Proceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022.. American Society of Mechanical Engineers (ASME), 2022. p. 1-11 V009T14A006.

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AB - Within this paper methods in reducing weight and optimizing the front-end structure, by specifically targeting both new materials and redesigning the cashbox, to improve crashworthiness were investigated. This was accomplished through redesigning the cross-sectional shape of the crash box, trigger location and type of trigger used, and the use of different materials. The optimal crash box design was found to be a hexagonal prism that incorporated a central trigger which reduced the thickness from 2mm to 1mm. Moreover, the ideal material was identified to be SGF/PA6/GnPls. When this optimized crash box was incorporated to the front-end structure and the ideal material applied to the bumper beam, the fully optimized front-end structure reduced the weight by 75%, reduced peak force by 28% and increased specific energy absorption by 94% and 55% for a frontal and side collision respectively.

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Elmarakbi M, Combrinck M, Elmasry A, Elmarakbi A. Design of a New Vehicle Front End Structure to Optimise Crashworthiness. In Proceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022.. American Society of Mechanical Engineers (ASME). 2022. p. 1-11. V009T14A006 doi: 10.1115/imece2022-95911

Design of a New Vehicle Front End Structure to Optimise Crashworthiness

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