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Steel and Composite Structures
  Volume 24, Number 3, June30 2017 , pages 351-358

Steel processing effects on crash performance of vehicle safety related applications
Emre Doruk

    Due to the increasing competition, automotive manufacturers have to manufacture highly safe and light vehicles. The parts which make up the body of the vehicle and absorb the energy in case of a crash, are usually manufactured with sheet metal forming methods such as deep drawing, bending, trimming and spinning. The part may get thinner, thicker, folded, teared, wrinkled and spring back based on the manufacturing conditions during manufacturing and the type of application methods. Transferring these effects which originate from the forming process to the crash simulations that are performed for vehicle safety simulations, makes accurate and reliable results possible. As a part of this study, firstly, the one-step and incremental sheet metal forming analysis (deep drawing + trimming + spring back) of vehicle front bumper beam and crash boxes were conducted. Then, crash performances for cases with and without the effects of sheet metal forming were assessed in the crash analysis of vehicle front bumper beam and crash box. It was detected that the parts absorbed 12.89% more energy in total in cases where the effect of the forming process was included. It was revealed that forming history has a significant effect on the crash performance of the vehicle parts.
Key Words
    steel processing; vehicle safety; crash analysis; forming history
(1) TOFAS-FIAT, R&D Department, 16369, Bursa, Turkey;
(2) Sakarya University, Department of Manufacturing Engineering, 54187, Sakarya, Turkey.

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