The Crumple Zone Quality Enhancement of Electric Cars Bumper Fascia using a Carbon Fiber Reinforced Vinyl Ester – Microsphere Composites

Sudirja, Sudirja; Hapid, Abdul; Kaleg, Sunarto; Budiman, Alexander Christantho; Amin, Ali

doi:10.1109/icseea47812.2019.8938633

Cited by 5 publications

(4 citation statements)

References 9 publications

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“…The stress simulation of hybrid composite-steel part for a chassis structure is the main interest of this paper. The mechanical properties used in this study were adapted from our previous investigation on the characterization of carbon fiber with microspheres filler [25]. It is known that the addition of such filler could add rigidity into the carbon fiber by a maximum strain of 1.17 % without any significant weight addition.…”

Section: Methodsmentioning

confidence: 99%

Stress Analysis Simulations of Welded and Bolted Joints Method for Full Steel and Composite-Steel Chassis Structure of Electric Low Floor Medium Bus

et al. 2020

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Stress analysis of welded steel-to-steel, bolted steel-to-steel, and bolted composite-steel chassis in an electric low floor medium bus structure is presented in this paper. The analysis was carried out on the condition that is when the bus is full of load in idle/static. This condition reflects the situation of the vehicle in full load with passengers and components, which is important to be analyzed to anticipate the unwanted structural failure of the chassis. Finite Element Method (Harmonic response simulation) is used to investigate the structural behavior of both welded and bolted methods. Several parameters such as 2 Hertz for the maximum frequency, 5000 kg for the total vehicle weight, and the uniform distribution of load are used for this study to simulate the simplified, real application in the real world. The first comparison is between the welded and bolted steel-to-steel chassis which results in the bolted method has a lower stress value by the difference of 4.3 MPa in the joint section than the welded joint. This means that the bolted joint is more recommended than welded for the use as an electric low floor medium bus and has the potential to be optimized further. In terms of reducing the weight of the chassis structure, then lightweight material (carbon fiber composite) is used to replace the full steel chassis to be a composite-steel chassis. The use of this hybrid material depicts the stress value of 61.5 MPa in the joint area, this value is still far below the limit of carbon fiber that is 3200 MPa makes this bolted composite-steel is considerably safe in full load condition as an electric low floor medium bus structure. Using this hybrid bolted composite-steel chassis structure also reduces the total chassis weight by about 22.7 % compared to the full steel chassis structure, thus one could expect to extend the mileage of electric vehicles by more than 20 %

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Section: Methodsmentioning

confidence: 99%

Stress Analysis Simulations of Welded and Bolted Joints Method for Full Steel and Composite-Steel Chassis Structure of Electric Low Floor Medium Bus

et al. 2020

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“…This qualification is known as crashworthiness. Almost every transportation mode uses this technology for optimizing their safety design, i.e., aircraft 26,27) , railways [28][29][30] , and automobiles 3,[31][32][33] . To meet the crashworthiness criteria, intense studies and analyses must be carried out carefully.…”

Section: Materials Properties and Crashworthiness Criteriamentioning

confidence: 99%

“…On the vehicle configuration, the crumple zone is the most common area in a vehicle that utilizes thin-walled technology. This is the zone where the structure of a car should be crumpled during the crash to minimize the injuries both for the driver and pedestrians 3) .…”

Section: Introductionmentioning

confidence: 99%

Crashworthiness Enhancement: The Optimization of Vehicle Crash Box Performance by Utilizing Bionic-Albuca Spiralis Thin-Walled Structure

Muhamad Arjuna Putra Perdana,

Sudirja,

Hapid

et al. 2023

Evergreen

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This paper presents a comprehensive investigation utilizing simulations to analyze the peak force and energy absorption characteristics of cylindrical configurations, as well as a novel spiral crash box design inspired by the albuca spiralis form. The study aims to evaluate the behavior of these designs in low-speed collisions by utilizing aluminum and steel as two different materials. Four primary forms of thin-walled structures, including concentric circles, tangent circles, halfbalanced circles, and spiral circles, were thoroughly examined using finite element analysis. Meshindependent tests were conducted to ensure the accuracy of the simulation results, and various crumple displacements were compared to determine the optimal mesh sizing. The numerical results demonstrate a significant reduction in peak force for the aluminum crash box, with a remarkable 60% decrease compared to the steel crash box. Furthermore, the spiral shape, identified as an optimized design, exhibits a low peak force of only 118.42 kN and offers superior energy absorption of 9.15 kJ per kilogram compared to the other designs. Consequently, employing nature-inspired designs provides substantial benefits for enhancing crashworthiness in energy-absorbing devices.

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“…Indeed, the use of lightweight materials is essential to lower the power consumption, particularly for hybrid and electric vehicles, hence, permitting them to fulfill sustainable mobility policies [4,5,[7][8][9]. Moreover, they may permit to meet more stringent safety requirements in case of impacts [10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Experimental Characterization of a High-Damping Viscoelastic Material Enclosed in Carbon Fiber Reinforced Polymer Components

Troncossi

Taddia²,

Rivola

et al. 2020

Applied Sciences

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This work aims to identify the damping properties of a commercial viscoelastic material that can be embedded and cured between the layers of composite laminates. The material may be adopted for reducing the vibration response of composite panels, typically used in automotive and aerospace applications, e.g. as vehicle body shell components. In order to objectively estimate the actual potential to enhance the noise vibration and harshness aspects, the effects of the viscoelastic material on the modal parameters of carbon/epoxy thin panels are quantitatively assessed through experimental modal analysis. Two different experiments are conducted, namely impact hammer tests and shaker excitation measurements. Based on the results of the experimental campaign, the investigated material is confirmed as a promising solution for possibly reducing the severity of vibrations in composite panels, thanks to its high damping properties. Indeed, the presence of just one layer proves to triple the damping properties of a thin panel. An approximate damping model is derived from the measured data in order to effectively simulate the dynamic response of new design solutions, including thin composite panels featuring the viscoelastic material.

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The Crumple Zone Quality Enhancement of Electric Cars Bumper Fascia using a Carbon Fiber Reinforced Vinyl Ester – Microsphere Composites

Cited by 5 publications

References 9 publications

Stress Analysis Simulations of Welded and Bolted Joints Method for Full Steel and Composite-Steel Chassis Structure of Electric Low Floor Medium Bus

Stress Analysis Simulations of Welded and Bolted Joints Method for Full Steel and Composite-Steel Chassis Structure of Electric Low Floor Medium Bus

Crashworthiness Enhancement: The Optimization of Vehicle Crash Box Performance by Utilizing Bionic-Albuca Spiralis Thin-Walled Structure

Experimental Characterization of a High-Damping Viscoelastic Material Enclosed in Carbon Fiber Reinforced Polymer Components

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