There is an ever-increasing demand in the automotive sector to continuously improve the performance and reduce cost through weight reduction in the structure of the vehicle. In the present scenario, it is also necessary to meet the standards set by crash safety regulating authorities in various parts of the world. In automobiles, the crash box is placed in the anterior region to absorb the impact energy in the event of an accident. Glass fiber reinforced plastic crash boxes have a high strength-to-weight ratio and also are good in energy absorption, particularly useful in this scenario. In this paper, the effectiveness of different triggers in combination with various geometries is investigated for Glass fiber reinforced plastic crash boxes using drop-weight impact testing. A trigger is a geometric irregularity introduced in the crash box design to alter the energy as well as force levels by modifying the deformation mode under loading. Comparison of change in force level, absorption of impact energy, specific energy absorption values was performed for composite crash boxes made of various types of cross-sectional geometries along with multiple patterns of triggers. Force versus displacement (F–D) curves are drawn for all the cases of the glass fiber reinforced plastic crash boxes to understand the behavior of each combination formed with various types of geometries and triggers, under impact loading. Strength-to-weight ratio was considered as the deciding factor for the comparisons to know the best and worst cases of the crash boxes made of different cross-sections along with various trigger types. This study provides detailed insights into the drop-weight impact testing procedure including the preparation of specimens, setting up the drop-weight impact test, preparation of specimen clamps, safety precautions involved, data acquisition from the test and its processing.
Abstract. The design and modeling of Low Stiffness Resilience Shaft (LSRS) for the Semi-Active Steering (SAS) system using wire ropes is discussed in this paper, along with the static structural torsion test simulation of the wire ropes in order to determine the best possible configuration which serves the purpose of an LSRS. The importance of this study arises due to the unidirectional torsional properties of a wire rope. For an effective operational LSRS, the wire ropes need to have similar angular deflection in both the clockwise and anti-clockwise direction. LSRS, an integral component of the SAS is a flexible shaft that can replace the conventional rigid shaft of the steering system and allows active control to be performed. 3D solid models of the simple strand and the 4 strand wire ropes used in finite element analysis were generated in CAD software SolidWorksTM. The single strand and the different configuration of wire ropes required to function the LSRS effectively were then analyzed using Finite element simulation in ANSYSTM. A single wire rope could not be used because its construction has inconsistency in the torsional stiffness in clockwise and anti-clockwise direction. The single-strand right-direction lay wire rope is found to have 16.05% angular deflection percentage difference in the clockwise and anticlockwise directions which indicates that using a single strand wire rope for the LSRS will cause the vehicle to have a variable response in the clockwise and anti clockwise direction upon turning the steering wheel. Due to this inconsistency, two variations namely Variation 1 and Variation 2 with arrangement of 4 strand wire rope were devised so that the angular deflection percentage difference would be negligible. Simulation results indicated that Variation 1 of the two variations with an angular deflection percentage difference of 0.34% in the clockwise and anti-clockwise direction respectively is best suited for the use in LSRS as it has almost negligible angular deflection percentage difference and will allow the vehicle to have similar steering response in the clockwise and anti-clockwise direction.
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