• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.3
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• pp.724-729
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• 2017

The crashworthiness of the fuel tank of a rotorcraft is verified through the crash impact test. The crash impact test has a high risk of failure due to the application of an excessive load, which can seriously affect the overall development schedule of the aircraft. Therefore, a lot of effort has been made to minimize the possibility of failure in the actual test by carrying out a numerical analysis of the crash impact test of the fuel tank in the initial design stage. Recently, an external auxiliary fuel tank was added to increase the cruising distance. In this study, the numerical analysis results of the crash impact test based on several different shapes of the external auxiliary fuel tank are presented, in order to evaluate its crashworthiness. For the numerical analysis, smoothed particle hydrodynamics (SPH), which is one of the fluid-structure coupled analysis methods, is applied and the test conditions prescribed by US military standards are reflected in the analysis conditions. In addition, the material property data previously obtained by the specimen test of the actual fuel tank is applied to the numerical analysis. As a result, the equivalent stress of the fuel tank material itself and the metal fitting is provided and the possibility of acquiring data for designing the crash-worthiness of the external auxiliary fuel tank is evaluated by examining the behavior and working load of the internal mounted components.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.3 s.234
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• pp.395-402
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• 2005

Recently Multidisciplinary Design Optimization Based on Independent Subspaces (MDOIS), an MDO (multidisciplinary design optimization) algorithm, has been proposed. In this research, an MDO problem is defined for design of a belt integrated seat considering crashworthiness, and MDOIS is applied to solve the problem. The crash model consists of an airbag, a belt integrated seat (BIS), an energy absorbing steering system, and a safety belt. It is found that the current design problem has two disciplines - structural nonlin- ear analysis and occupant analysis. The interdisciplinary relationship between the disciplines is identified and is addressed in the system analysis step in MDOIS. Interdisciplinary variables are belt load and stiffness of the seat, which are determined in system analysis step. The belt load is passed to the structural analysis subspace and stiffness of the seat back frame to the occupant analysis subspace. Determined design vari- ables in each subspace are passed to the system analysis step. In this way, the design process iterates until the convergence criterion is satisfied. As a result of the design, the weight of the BIS and Head Injury Crite- rion (HIC) of an occupant are reduced with specified constraints satisfied at the same time. Since the system analysis cannot be formulated in an explicit form in the current example, an optimization problem is formu - lated to solve the system analysis. The results from MDOIS are discussed.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.3
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• pp.32-38
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• 2020

This study examined the problems of existing vehicles to propose alternatives to improve the crashworthiness of railway freight cars through collision acceleration analysis using a one-dimensional collision analysis method. A collision scenario of railway shunting and crash accidents was selected from the collision accident cases and international standards. A one-dimensional collision simulation using LS-DYNA was performed according to those scenarios. As a result, the acceleration level of the freight wagon was calculated to be under 2g and was predicted to meet the EN 12663 standard in the shunting situation. On the other hand, the result of crash simulation with an impact velocity between 10 and 15 km/h revealed the shock absorber capacity of the railway coupler to be insufficient in a crash situation, resulting in increased acceleration, and carbody deformation could be predicted. As a method of improving the crashworthiness, a deformation tube-type energy absorber was applied to the coupler system, and collision analysis was performed again with new energy absorption strategy. Overall, the simulation showed that the acceleration level was decreased by 12% of the conventional freight-car energy absorption system.

• International Journal of Precision Engineering and Manufacturing
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• v.5 no.4
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• pp.61-68
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• 2004

Necessity to address engineering system uncertainties in design processes has long been acknowledged. To obtain quality of product, a safety factor is traditionally used by many design engineers due to its easy of use and comprehension. However, the safety factor approach often yields either conservative or unreliable designs, since it ignores the type of probability distribution and the mechanism of uncertainty propagation from the input to the output. For a consistent reliability-based design, two fundamental issues must be investigated thoroughly. First, the design-decision process that clearly identifies a mechanism of uncertainty propagation under system uncertainties needs to be developed, which must be an efficient and accurate process. To identify the mechanism more effectively, an adaptive probability analysis is proposed by adaptively setting probability levels through a posteriori error estimation. The second is to develop the design process that not only yields a high quality design but also a cost-effective optimum design from manufacturing point of view. As a result, a response surface methodology is specially developed for RBDO, thus enhancing numerical challenges of efficiency and complicatedness. Side crashworthiness application is used to demonstrate the integrated design process for product and manufacturing process design.

• Journal of Auto-vehicle Safety Association
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• v.13 no.4
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• pp.92-98
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• 2021

Recently hydrogen fuel cell buses have been deployed for the public transportations. In order to introduce buses fueled by hydrogen successfully, the research results of hydrogen bus safety should be discussed and investigated significantly. Especially, Korean government drives research in terms of various applications of hydrogen energy to replace the conventional fuel energy resources and to improve the safety evaluation. Thus it is necessary to examine vehicle crashworthiness under side impact loadings. This study was focused on the simulation result evaluation of full bus model and simplified bus model with hydrogen fuel tank module and mounting system located below floor structure due to the significance of bus side impact accidents. The finite element models of hydrogen bus, fuel tank system and side impact moving barrier were set up and simulation results reported model performance and result comparison of two side impact models. Computational results and research discussion showed the conceptual side impact framework to evaluate hydrogen bus crashworthiness.

• Proceedings of the KSR Conference
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• 2006.11b
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• pp.11-17
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• 2006

In this paper, crashworthiness of EMU carbody against overhead line structure is numerically evaluated. The material of the EMU carbody is made of stainless steel(SS301L). The material of the overhead line structure(a portal-type) is structure steel (SS400). The EMU carbody is numerically analyzed under collision conditions such as upright side-on impact scenario and angled impact scenario to collide against overhead line structure(a portal-type) at 64.6 kph, respectively.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.22 no.5
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• pp.128-135
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• 2021

Thin-walled tubes have been widely used as energy absorbing devices because they are light and have high energy-absorption efficiency. However, the downside is that conventional thin-walled tubes usually exhibit an excessive initial peak crushing force (IPCF) and a large fluctuation in the load-displacement curve, and thus lack stability as energy absorbing devices. Corrugated tubes were introduced to reduce IPCF and to increase the stability of collision energy-absorbing devices. Since the performance of corrugated tubes is highly influence by geometry, design optimization methods can be utilized to optimize the performance of corrugated tubes. In this paper, we utilize shape design optimization based on an adaptive surrogate model for crashworthiness analysis. The amplitude and wavelength of the corrugation, as well as curvature changes in the features, are the design variables. A morphing methodology is adopted to perform shape design parameterization. Through numerical examples, we compare optimal design results based on the adaptive surrogate model, with optimal results based on conventional surrogate models, and we show that direct optimal design methods produce more efficient results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.266-269
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• 2003

This paper is concerned with a forming analysis of front side members and the application of the forming effect in crash analysis of auto-body. Drawbead restraining forces are calculated with ABAQUS/Strandard in order to identify the boundary condition in forming process. Forming analysis with equivalent drawbead is carried out with LS-DYNA3D. In order to demonstrate the validity of the forming analysis, quantitative comparison of the thickness variation between the real product and the numerical simulation result is carried out. Forming histories obtained from the forming analysis are utilized as the initial condition of the crash analysis for accurate assessment of the crashworthiness.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.457-464
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• 2002

A finite element inverse analysis is utilized to consider forming effects of an S-rail on the assessment of the crashworthiness with small amount of computation time. A crash analysis can be directly performed after the inverse simulation of a forming process without a smoothing or remeshing scheme. The direct mesh mapping method is used to calculate an initial guess from a sliding constraint surface that is extracted from the die and punch set. Analysis results demonstrate that energy absorption of structures is increased when simulation considers forming effects of thickness variation and work hardening. The finite element inverse analysis is proved to be an effective tool in consideration of forming effects for the crash analysis.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.1156-1161
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• 2008

Nonlinear dynamic analysis is generally used in automobile crash analysis and structural optimization considering crashworthiness uses the results of nonlinear dynamic analysis. Automobile crash optimization has high nonlinearity and difficulty in calculating sensitivity. Recently the equivalent static load (ESL) method has been proposed in order to overcome these difficulties. The ESL is the static load set generating the same displacement field as the nonlinear dynamic displacement field at each time step in dynamic analysis. From various researches regarding the ESL method, it has been proved that the ESL method is fairly useful. The ESL method can mathematically optimize a crash optimization problem through nonlinear analysis and well developed static optimization. The ESL is applied to nonlinear dynamic structural optimization of the automobile frontal impact problem. An automobile bumper is optimized. The mass of the structure is minimized while some constraints are satisfied.