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Integration of Hydroforming Analysis of Front-End Structures Into Full Vehicle Crash Analysis

[+] Author Affiliations
Kumar Mahadevan, Omar Faruque, James Cheng

Ford Motor Company, Dearborn, MI

Yishan J. Qiu

Engineering Technology Associates

Barry L. Dombek

Dana Corporation, Toledo, OH

Paper No. IMECE2002-39107, pp. 335-343; 9 pages
  • ASME 2002 International Mechanical Engineering Congress and Exposition
  • Transportation: Making Tracks for Tomorrow’s Transportation
  • New Orleans, Louisiana, USA, November 17–22, 2002
  • Conference Sponsors: Transportation
  • ISBN: 0-7918-3656-8 | eISBN: 0-7918-1691-5, 0-7918-1692-3, 0-7918-1693-1
  • Copyright © 2002 by ASME


Changes in gauge and material properties are the trademarks of hydroforming process used for any parts. These changes may be large enough to affect the vehicle responses under impact loading in a significant way. An investigation was carried out to determine how full vehicle crash responses are affected by these changes and the findings are reported in this paper. Key to this study has been a methodology to map the gauge and property changes, obtained from a forming simulation, to FEA models created for crash analyses. The mapping process thus allows one to consider the property and gauge changes as an initial condition during crash simulation. A number of full vehicle crash simulations were conducted and the results are compared with the corresponding test data. The entire procedure has been verified using the CAE models developed for simulating hydroforming and frontal impact behavior of a vehicle program. The implementation of the developed methodology to other vehicle programs is straightforward.

Copyright © 2002 by ASME
Topics: Vehicles



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