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

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Front End Division

Perimeter:Carrier (bolster)Engine Cooling ModuleAir driversBumper beamPedestrian beamWasher-tankHood-latchHornWiring harnessHood sealBump stopsFascia

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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.

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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

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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)

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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

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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

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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

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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

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Lower leg impact summary results

-33.24%-52.15%

-40.67%

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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%

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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

“I hear, I knowI see, I remember,

I do, I understand.”(Confucius, 551BC – 479)

marcelo.fonseca-barbosa@valeo.com+33.1.30.13.52.27