An Improvement Of The Side Crash Of TFC-H1 Car Based On The CAE Analysis

With the rapid development of economy, energy and environmental problems have been highlighted in the global scale, the vehicle as one of the important energy consumption mode has also been paid more attention. In such circumstance, the economical car has received more preferential policies, and the advantages of economical car began to become apparent. However, the consumers don't just focus on energy-saving, the economical car which has higher security trait has been more popular.Tianjin FAW is the production base of economical car, its brand is very famous in the country wide. This paper has summarized the research and development works that Tianjin FAW Xiali Automobile Co., Ltd. has done in recent years to improve the safety for the body structure of a new-generation models (TFC-H1) , and has explored the effect that the floor frame structure has done for the side impact safety.This article first described the main elements and criterion of the side impact regulations that has been developed by our country, including the collision mode, test dummy, injury indicators and the movable barrier, and has done some comparison with foreign regulations. To shorten the development cycle and avoid risks, we have done the real vehicle side impact test using a prototype vehicle. We focused on the analysis of the floor frame deformation of prototype cars and the dummy's injury data in the side impact test. By this way, we have determined the weak position of fool frame for the prototype car and have provided a theoretical basis for its improvement.By studying the modern anti-collision structure, as well as the improvement methods commonly used, we proposed the following methods for the improvement of floor frame structure: 1. Improved the side beams structure and has replaced its material to increase strength;2. Strengthened the beams under front floor, and connect them with the No.1 beam of rear floor, to form an effective collision energy transfer path;3. Redesigned several board of the central channel;4. Strengthened the structure of front floor beams;5. Strengthened the floor structure under the seats, to prevent turning of seats;6. Increased inner board of rear floor longeron, and strengthened the structure of rear floor No.1 beam;Subsequently, this article has done the side impact of TFC-H1 by CAE tools, and has introduced finite element mesh methods, unit inspection and the setting of initial conditions. By the comparative analysis of two sets of the structure improvement scheme, we discussed the influnce of floor fram design and B pillar design for the anti-collision improvement. The No.2 method has improved side impact safety of TFC-H1, and the real vehicle collision tests has also verified the effectiveness of this program.Finally, we proposed the following directions in the field of body structure design which is worthy of further research and development:1. Building the database of car body components;2. Modularize and Standardize the key components that play an important role in the security of car body;3. Do more research on advanced design methods, such as virtual design and concurrent design, etc.