A Simulation Study Of The Crashworthiness Of Automobile Crash Box Based On Stamping

With the continuous advancement of the process of economic globalization and the rapiddevelopment of modern science and technology, domestic and foreign automobile companiesare facing unprecedented challenges in the design and development of automobile. Thedomestic automobile market is becoming increasingly competitive, as the government wantsrigorous implementation of environmental standards. Meanwhile, the customer requirementsare becoming more extensive and demanding. The customers now are more concerned aboutsafety along with price, appearance and other aspects related to performance of the vehicle.Environmental protection, energy conservation and safety have become the most concernedtopic when researching and developing automobile, as modern automobiles are now highspeed and light weight machines.The research objective of this paper is to improve the design of automobile crash box byusing finite element simulation method. The results from stamping were mapped to thestructure of the collision simulation model, and the crash simulation tests were performed.The effects of stamping on the crashworthiness of automobile crash box were analyzed toimprove the accuracy and effectiveness of the automobile crash finite element simulation. Thefollowing specific research work：First of all, automobile body structures and energy-absorbing deformation zones werestudied. The evaluation standards of automotive bumper systems were briefly described. Toperform the finite element simulation, the collision simulation model was refined, along withmeshing and material definition. The shape and pattern of welding fabrication of automobilecrash box was studied to improve the crashworthiness of automobile crash box.Secondly, literature related with the basic theory of stamping and its finite elementanalysis was reviewed. The automobile crash box was stamped using the incrementalstamping software DynaForm. The stamping simulation results of three molding ways of thecrash box were compared and analyzed and the formability of three kinds of typical materialswere evaluated.Finally, the results from stamping simulation, such as the plastic strain, residual stressand thickness distribution, were mapped to the structural model of crash simulation. ThenLS-DYNA software was used to solve the effects of stamping on energy absorption, impact force and deformation result of automobile crash box. The results show that stamping hasimproved the crashworthiness of automobile crash box.