Front End Division
A plastic absorber structure optimizationfor lower leg protection application
Marcelo FONSECA BARBOSA*Sébastien GUINEHUT
*speaker
Property of Valeo – Duplication prohibitedOctober 2007
Contents
Front End Division
Pedestrian protection
Lower leg problem
Model and Hyperstudy setup
Results review
Conclusion
Property of Valeo – Duplication prohibitedOctober 2007
Front End Division
Perimeter:Carrier (bolster)Engine Cooling ModuleAir driversBumper beamPedestrian beamWasher-tankHood-latchHornWiring harnessHood sealBump stopsFascia
Property of Valeo – Duplication prohibitedOctober 2007
Front End Mission
Develop and deliver in sequence and in just in time Front End Modules to The OEM production sites.Valeo has created a new division in 1998 to follow the new customers’ procurement strategy.
Property of Valeo – Duplication prohibitedOctober 2007
Front End Production
Valeo FEM Annual Production1 900 000 modules in 2007
1 900 000
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Worldwide presence
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Antagonist market needs
Fit & Finish (zero gap design)Fit & Finish (zero gap design)
Reduced weight
NVH
Compactness(over-hang and bonnet height)
Reduced weight
NVH
Compactness(over-hang and bonnet height)
Low repair cost
Pedestrian protection
Crash compatibility
Low repair cost
Pedestrian protection
Crash compatibility
Air-flow efficiencyAir-flow efficiency
Property of Valeo – Duplication prohibitedOctober 2007
Contents
Front End Division
Pedestrian protection
Lower leg problem
Model and Hyperstudy setup
Results review
Conclusion
Property of Valeo – Duplication prohibitedOctober 2007
Pedestrian protection
Biomechanical impactors and criteria
Adult / Child headUpper leg
Lower leg
Bending (°)
Shearing (mm)
Deceleration (g)
Force and Bending moment (∑F; M)
HeadInjuryCriteria (HIC)
Property of Valeo – Duplication prohibitedOctober 2007
EC Directive
The EC Directive is (then) a 2 step approach which led to the introduction of legislation with Phase 1 in 2005 and a more stringent Phase 2 in 2010 under directive 2003/102/EC
Phase 1 : all new car model from 10/2005 (new type for vehicle entering EU)Phase 2 : 80% car (model) from 01/07/2010, 90% car (model) from 01/07/2011 and 100% from 31/12/2012
Bio mechanical criterion limitsEC Directive
IMPACTS CRITERIA UNITS Phase 1 Phase 2Acceleration g 200 150
Rotation ° 21 15Shearing mm 6 6
Force kN Monitoring 5Bending Moment Nm Monitoring 300
Child Head Form Acceleration HPC 2/3 area <10001/3 area <2000
<1000
TARGET
Lower Impact
Upper Leg
Property of Valeo – Duplication prohibitedOctober 2007
Consequences on vehicle packaging
Upper Leg:• Rigid Points (upper beam, headlamps, side rails)
• No Space
• No energy Absorber
Lower Leg:• No energy absorber
• No pedestrian beam
Child Head:• Rigid Points( Hood, latch, engine)
• No space
Property of Valeo – Duplication prohibitedOctober 2007
Consequences on vehicle packaging
140mm of absorbing space, free of hard points (heat exchanger, latch…)
Add ~95 mm* of absorbing material in front of the bumper beam
Add a pedestrian beam for lower leg impact
Low
erle
gU
pper
leg
Vehicle cross section* EC - Phase 2
Property of Valeo – Duplication prohibitedOctober 2007
Contents
Front End Division
Pedestrian protection
Lower leg problem
Model and Hyperstudy setup
Results review
Conclusion
Property of Valeo – Duplication prohibitedOctober 2007
Lower leg problem
A light plastic absorber structure was created to replace a foam absorberEC-phase 2 is the targetThe initial packaging is 80 mm
OBJECTIVEReduce weight
Reduce packaging
Improve performance
Property of Valeo – Duplication prohibitedOctober 2007
Contents
Front End Division
Pedestrian protection
Lower leg problem
Model and Hyperstudy setup
Results review
Conclusion
Property of Valeo – Duplication prohibitedOctober 2007
Model set-up
Radiossmodel(D00)
Hypermeshmodel (.hm)
Full modelPlastic absorber
PARAMETERS
3 Shape
4 thickness
HyperStudy
<Type>HM</Type><PreModel>MODEL.hm</PreModel><Solver>Radioss44blk</Solver><InputDeck>ABSORBD00</InputDeck><RunScript>scr_5</RunScript>
PARAMETERS
3 Shape
4 thickness
LOWER LEGresponses
OBJECTIVE FUNCTIONCRITERIA
based on 3 lower legresponses
ABSORBD00Radiossmodel(D00)
HyperStudy
RADIOSS
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Shape parameters
Dimensions:
Upper plate longitudinal– From 70 mm to 34 mm
Lower plate longitudinal– From 70 mm to 36 mm
Back plate vertical
– From 113 mm to 80 mm
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Thicknesses parameters
Upper
Lower
Back
Vertical ribs
Thickness range: 1.7 – 4.0 mm
Property of Valeo – Duplication prohibitedOctober 2007
Contents
Front End Division
Pedestrian protection
Lower leg problem
Model and Hyperstudy setup
Results review
Conclusion
Property of Valeo – Duplication prohibitedOctober 2007
Lower leg impact summary results
-33.24%-52.15%
-40.67%
Property of Valeo – Duplication prohibitedOctober 2007
Geometry
1st = 113 mm15th = 101.91 mm
1st = 70 mm15th = 57.07 mm
1st = 70 mm15th = 57.64 mm
1st = 2.5 mm15th = 2.07mm
1st = 2.5 mm15th = 1.7 mm
1st = 2.5 mm15th = 1.99 mm
1st = 3.0 mm15th = 1.9 mm
494.1g → 305.1g► - 38.25%
Property of Valeo – Duplication prohibitedOctober 2007
Animation
83 247 nodes11 material cards48 parts8 476 solid elements65 586 quad elements3 012 tria elements1 140 spring elements95 interfacesTime step = 2.5·10-4 ms
Property of Valeo – Duplication prohibitedOctober 2007
Contents
Front End Division
Pedestrian protection
Lower leg problem
Model and Hyperstudy setup
Results review
Conclusion
Property of Valeo – Duplication prohibitedOctober 2007
Conclusion
Size and shape optimization is the key for best performance and cost reductionIntelligent morphing helps shape variation with time step controlModel sub-division held less disk space usageHyperStudy optimization routines reduces the number of iterations
Property of Valeo – Duplication prohibitedOctober 2007
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Thank you for your attention
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