Crashworthiness Simulation of Automobile Front Rail Assembly with Consideration of Sheet Forming History

Abstract:

The thickness thinning,residual stress and effective plastic strain resulted from sheet metal forming process were introduced into the crashworthiness simulation of a front side rail assembly in this work.Influences of these forming effects on the energy absorption and reaction force were analyzed in detail.The main factors determining the calculation precision and its efficiency were discussed.Results show that the internal energy with a consideration of the forming history is larger than that neglecting the forming history.And the peak force is larger and late.Among the thickness,the residual stress and the effective plastic strain,the thickness is the most significant factor for the energy absorption and the residual stress and effective plastic strain are important factors for the reaction force.

Key words:sheet forming history; crashworthiness simulation; front rail; mapping