Side impact evaluation with high performance polymers and improved design of impact beam as per FMVSS-214 regulations

Abstract

This study describes the development of a new side-impact beam design with high-performance polymer/plastic materials. The new designs are analyzed and contrasted with the original side impact beam made from conventional steel material. The novel designs are assessed on a wide range of parameters to make sure that occupant safety is not compromised. Three different high-performance plastic materials (LCP-CF-30, PA6-CF-30, and PA66-GF-60) are considered. The methodological framework of Finite Element Analysis (FEA) is used for numerically computing, analyzing, evaluating, and refining the new side-impact bar designs. This study accordingly examines and quantifies the detailed effects of the collision on the side-impact beams of different designs. The design and the material with the desired result are then integrated into a typical passenger car Finite Element Model, and computational impact evaluation tests and analysis are carried out as per Federal Motor Vehicle Safety Standard (FMVSS-214). The results from the Moving Deformable Barrier (MDB) and the Rigid Pole tests, including parameters such as intrusions, accelerations, and ratings are determined as per Insurance Institute for Highway Safety (IIHS) side-impact structural safety guidelines. High-performance plastics-based side-impact beams are shown to exhibit considerable reductions in intrusions and accelerations in the tested FE models. Of all the designs and materials tested, the designs based on LCP-CF-30 material are shown to exhibit the most reductions in intrusion and accelerations on side-impact beams. Inferring from the MDB and Rigid Pole tests, the study concludes that the novel LCP-CF-30 based side-impact beam provides improved safety when contrasted with that of the original steel side-impact beam. This study also demonstrates that when used with appropriate designs, high-performance plastics can be quite effective in producing components with desired energy absorption capabilities and significant reductions in displacements and mass.