Integration of the forming effects into vehicle front rail crash simulation

The accuracy of crash simulation is critical to evaluating the design of a vehicle, especially for energy-absorption capacity and crash mode. Hence, it is necessary to integrate the forming effect into crash model as a key input. In this study, the front rail, a typical thin-walled beam structure which was assembled in a passenger vehicle, was observed for its important role of absorbing kinetic energy in the vehicle frontal impact. Comparison between front rail crash simulation model (1) with no forming effect, (2) considering forming effect, and the result of sled impact test shows that the hardening effect from the forming history strengthens the component, and thus significantly influences the crash mode of the front rail.