Development of high crush efficient, extrudable aluminium front rails for vehicle lightweighting

Kohar, Christopher P.; Zhumagulov, Amir; Brahme, Abhijit; Worswick, Michael J.; Mishra, Raja K.; Inal, Kaan

doi:10.1016/j.ijimpeng.2016.04.004

Cited by 63 publications

(20 citation statements)

References 39 publications

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“…Smerd et al [19] have reported that automotive aluminum alloys generally exhibit low strain-rate sensitivity at room temperatures. Yet, aluminum alloys start to exhibit positive rate sensitivity at moderate and high strain-rates due to a change in temperature through adiabatic heating [3,20]. As such, the Cowper-Symonds coefficients of = 9.39 × 10 Fu EF and = 10.55 are used for all materials in this study [21].…”

Section: Sampling Of Component Grouping Thickness and Materials Propermentioning

confidence: 99%

“…However, it should be noted that this requires the use of the GPU to achieve these computational gains. Nevertheless, this significant reduction in computational time can aid scientists and engineers in developing lightweight solutions when coupled with an intelligent optimization framework [3].…”

Section: Sampling Of Component Grouping Thickness and Materials Propermentioning

confidence: 99%

“…However, automotive engineers must consider passenger safety in conjunction with vehicle lightweighting [3]. In the event of a vehicle collision, a crash pulse wave is generated and propagated throughout the vehicle.…”

Section: Introductionmentioning

confidence: 99%

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Using Artificial Intelligence to Aid Vehicle Lightweighting in Crashworthiness with Aluminum

et al. 2020

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Significant efforts have been made in the automotive industry to reduce vehicle weight in order to improve vehicle fuel economy and reduce greenhouse gas emissions. New innovations in structural lightweight alloys and manufacturing techniques have allowed automakers to replace conventional steel with lighter aluminum structures. However, automakers have an enormous number of material and gauge thickness combinations to consider in the development process of the next generation production vehicle. Furthermore, the design combination of these materials and structures must not compromise the integrity of the vehicle during a vehicle collision. With the proliferation of inexpensive computational resources, automakers can now explore the effect of material selection on the crashworthiness of next-generation vehicles using computer simulations. While information from these simulations can be manually extracted, the vast amount of data lends itself to artificial intelligence (AI) techniques that can extract knowledge faster and provide more useful interpretations that can be convenient for designers and engineers. This work presents a framework for using artificial intelligence to aid the vehicle design cycle in crashworthiness using aluminum. Virtual experiments of a frontal crash condition of a pick-up truck are performed using finite element analysis to generate the data for this method. Different commercially available aluminum alloys and gauge thicknesses are varied in the virtual experiments. An advanced type of recurrent neural network is used to predict the time-series response of the occupant crash-pulse response, which is a key crashworthiness metric that is used for evaluating safety. This work highlights how automotive designs and engineers can leverage this framework to accelerate the development cycle of the next-generation lightweight vehicle.

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Section: Sampling Of Component Grouping Thickness and Materials Propermentioning

confidence: 99%

Section: Sampling Of Component Grouping Thickness and Materials Propermentioning

confidence: 99%

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Using Artificial Intelligence to Aid Vehicle Lightweighting in Crashworthiness with Aluminum

et al. 2020

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“…Kohar et.al. [10] presented a framework for optimizing the sizing of a multi cellular aluminium extrusion for automotive crashworthiness application. New aluminium extrusion profile were designed using finite element, fabricated and dynamically crushed using a slid-track apparatus.…”

Section: Fig 4 First Contact Zone In Pedestrian-vehiclementioning

confidence: 99%

A Study on Design and Crash Analysis of Automotive Energy Absorption Tubes

H¹,

Desai²

2019

Journal of Manufacturing Engineering

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In engineering and technology safety of human life has always been a top priority. With the increasing usage of vehicles in everyday life, probability of deaths and injuries has also increased, but safety is important too. The main aim of this study is for designing an energy absorption tubes (Crush Can) of different shapes, thickness, at 10 km/hr speed and checking its performance by numerical simulation on the basis of FMVSS by using Finite Element Analysis and evaluate the result by changing design of Crush Can in the form of stress, energy graphs are plotted, by comparison of results, we can suggest that 1mm thickness and circular design absorb optimum stress and more energy than other. The HYPERMESH software is used in meshing and LS-DYNA software is used as a solver

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“…They obtained a maximum crushing force efficiency of 11.6%, which was higher than that of the square tubes made with the same material. Kohar et al [6] developed optimized sectional sizes of extrusion profiles using a multicellular 6063-T6 aluminum alloy with finite elements and neural network metamodeling. The new profile had a higher mean crush force that showed a 26.7% increment in energy absorption than that in the initial size.…”

Section: Introductionmentioning

confidence: 99%

Effect of Zn and Mg Content on Crashworthiness of Al-Zn-Mg Alloy Thin-Walled Square Extrusions

et al. 2020

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The effects of Zn and Mg content in thin-walled square extrusions of Al-Zn-Mg alloys on its crashworthiness were investigated, and the correlation between the crushing properties, mechanical properties, and microstructures of the profiles were investigated. The results showed that the strength and the compression properties were gradually increased with a decrease in the Zn/Mg ratios (from 12.48 to 4.57). When the Zn/Mg ratio is lower (less than 6.29), an increase in the Mg content simultaneously improves the alloy strength and the compression properties. An increase in Zn content (from 5.07 to 6.77) can improve the strength of the alloy however, it does not affect the compression properties. However, the higher Zn contents (6.77%) would lead to cracking in advance during the compressing, which reduces the compression energy absorption capacities of the product. Therefore, in order to obtain higher strength and excellent compression properties, the Zn/Mg ratio should be reduced. For the upper limit, the Zn content should not be too high (less than 6.77), as this may lead to early cracking and failure. For the lower limit, the Mg content should be higher (more than 0.91) to make sure that the alloy has excellent compression properties and higher strength.

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Development of high crush efficient, extrudable aluminium front rails for vehicle lightweighting

Cited by 63 publications

References 39 publications

Using Artificial Intelligence to Aid Vehicle Lightweighting in Crashworthiness with Aluminum

Using Artificial Intelligence to Aid Vehicle Lightweighting in Crashworthiness with Aluminum

A Study on Design and Crash Analysis of Automotive Energy Absorption Tubes

Effect of Zn and Mg Content on Crashworthiness of Al-Zn-Mg Alloy Thin-Walled Square Extrusions

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