Analysis And Simulation On Impact Collision Of Multi-Purpose Vehicle (MPV) As NGV.
ANALYSIS AND SIMULATION ON IMPACT COLLISION OF MULTI-PURPOSE VEHICLE (MPV) AS NGV
MOHD AMIRUL BIN AWANG
A thesis submitted in fulfillment of the requirements for the award of the degree of bachelors of mechanical engineering (automotive)
Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka
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“I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in terms of scope and quality for the award of the degree of Bachelors of
Mechanical Engineering (Automotive).”
Signature : ...
Name of Supervisor : MR. MOHD ZAID BIN AKOP
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ANALYSIS AND SIMULATION ON IMPACT COLLISION OF MULTI-PURPOSE VEHICLE (MPV) AS NGV
MOHD AMIRUL BIN AWANG
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“I declare that this thesis is my own research except cited in the references and each of it was explained their source.”
Signature : ...
Name : MOHD AMIRUL BIN AWANG Date : 8 MAY 2009
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ACKNOWLEDGEMENT
All praise is to Allah, the Almighty with whose gracious help it was possible to accomplish this project.
I wish to express my deepest gratitude and sincere appreciations to my supervisor Mr. Mohd Zaid bin Akop, for his academic thought suggestion and input throughout the duration of this Final Year Project. Without his continued support and interest, this thesis would not have been the same as presented here. I wish to acknowledge the encouragement and advice I have received from him.
Special thanks to my previous supervisor Mrs Rafidah binti Hasan who had been a good supervisor. I greatly appreciate her care and dedication in constructively criticizing my work. Also thanks a lot to all my friends for their support.
Last but not least, I am grateful to my beloved family especially to my parents whom always encourage and support me in my studies. Thanks for their care and love for over twenty years.
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ABSTRAK
Projek ini sebenarnya mengusulkan tentang pembelajaran, analisis dan membuat simulasi tentang impak perlanggaran pada kenderaan pelbagai guna (MPV) yang dilengkapi sistem gas asli untuk kenderaan (NGV). Simulasi ini bertujuan untuk menunjukkan perbezaan kerosakkan struktur kenderaan di antara kenderaan pelbagai guna yang dilengkapi sistem NGV dan tanpa di lengkapi sistem NGV apabila perlanggaran berlaku. Untuk simulasi ini, kedua – dua model kenderaan ini di uji dengan melanggar tembok pegun secara perlanggaran depan sepenuhnya pada kelajuan 80 kilometer per jam mengikut spesifikasi yang di tetapkan. Dengan menggunakan perisian ABAQUS, struktur kerangka kenderaan telah dirangkakan. Kemudian, simulasi kenderaan tersebut di lakukan menggunakan perisian ABAQUS bagi menunjukkan kestabilan atau analisis beban dan juga impak tenaga yang terhasil apabila perlanggaran tersebut berlaku. Keputusan yang di perolehi menunjukkan bahawa kenderaan yang di aplikasikan dengan menggunakan sistem NGV akan mempunyai momentum yang lebih besar disebabkan penambahan berat kenderaan dan menghasilkan impak dan kerosakkan struktur yang lebih besar berbanding dengan kenderaan tanpa menggunakan sistem NGV ini ketika perlanggaran.
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ABSTRACT
This project actually to study, analyze and show the simulation about the impact of collision on multi-purpose vehicle (MPV) as NGV (Natural Gas Vehicle). The simulation will shows the comparison about the vehicle’s structure damage between the MPV that was applied with the NGV system and MPV without the NGV system when the collision occurred. For this simulation, both vehicle models were tested to crash the static barrier from the front side with full-width crash at 80 kilometer per hour with the standard specification. By using ABAQUS software, the vehicle frame was designed. Then, the simulation was created by using ABAQUS software to show the load analysis and energy absorb that was produced when the vehicle in the collision situation. The result show the vehicle that was applied by the NGV system will produce a big momentum due to the increasing of vehicle’s weight and give a big effect on structure damaging compare to the vehicle without applying the NGV system during collision.
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TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRAK v
ABSTRACT vi
TABLES OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF SYMBOLS xv
LIST OF ABBREVIATIONS xvi
LIST OF APPENDICES xvii
CHAPTER I INTRODUCTION 1
1.1 General Overview 1
1.2 Problem Statement 2
1.3 Objective 3
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CHAPTER TITLE PAGE
1.5 Planning of Research 3
CHAPTER II LITERATURE REVIEW 4
2.1 Vehicle Safety History 4
2.2 Vehicle Structure 6
2.3 Structure Material 7
2.4 Crashworthiness 7
2.5 Crashworthiness Goal 8
2.6 Structure Test 8
2.7 Frontal Crash Tests 9
2.8 Effect Mass to Crash 11
2.9 NGV Application 12
2.10 Physic Theory 13
2.11 Previous Research of Crash Test 15
CHAPTER III METHODOLOGY 18
3.1 Project Methodology 18
3.2 Flow Chart of Methodology 19
3.3 Finding Literature Review 20
3.4 MPV Parameter Data 20
3.5 Defining MPV Frame 21
3.6 Computational Modeling 23
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CHAPTER TITLE PAGE
3.6.2 Defining Part’s Material 24 3.6.3 Part Section Material
and Section Assignment 24
3.6.4 Part Assembly 25
3.6.5 Part Constraint 27
3.6.6 Defining Reference Point and Set 29
3.6.7 Step 30
3.6.8 Output Request 31
3.6.9 Defining Surface 33
3.6.10 Interaction Properties 33
3.6.11 Predefined Field 35
3.6.12 Defining Mass and Load 37
3.6.13 Boundary Condition 39
3.6.14 Mesh Seed 40
3.6.15 Mesh Control 41
3.6.16 Mesh Element 41
3.6.17 Mesh Instance 43
3.6.18 Job and Visualization 43
CHAPTER IV RESULT AND DISCUSSION 44
4.1 Introduction 44
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CHAPTER TITLE PAGE
4.2.1 MPV Frame without NGV 45
4.2.2 MPV Frame with NGV 50
4.3 Discussion 55
4.3.1 Force Comparison 55
4.3.2 Displacement Comparison 57 4.3.3 Energy Changes Comparison 58 4.3.4 Kinetic Energy Comparison 61 4.3.5 Energy Absorb Comparison 61
CHAPTER V CONCLUSION AND RECOMMENDATIONS 62
5.1 Conclusion 62
5.2 Recommendations 64
REFERENCES 65
BIBLIOGRAPHY 67
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LIST OF TABLES
TABLE NO TITLE PAGE
2.1 Comparison of NGV cylinder weight 12
(Source: Faber Industries S. P. A., (1998 – 2008))
3.1 MPV Parameter 21
(Source: Kia Motor, (2008))
3.2 Material Properties 24
4.1 Comparison of Maximum Force 55
4.2 Comparison of Displacement 57
4.3 Comparison Maximum of Energy Changes 59
4.4 Kinetic Energy Comparison 61
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LIST OF FIGURES
FIGURE NO TITLE PAGE
2.1 Full-Width Crash Test 10
(Source: FHWA/NHTSA National Crash Analysis Center, (2003))
2.2 MPV with NGV System 13
(Source: NGV Network Malaysia, (2008))
3.1 Project Development Activities Phases 19
3.2 MPV Naza RIA Model 20
(Source: Kia Motor, (2008))
3.3 Plate Element Dimension 22
3.4 Radius of Circular Beam 22
3.5 Wire frame Part 23
3.6 Frame Profile 25
3.7 Complete Assembly Frame and Barrier 27
3.8 Parts Constraint 28
3.9 Creating Set 29
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3.11 Defining Step 30
3.12 Field Output Request 32
3.13 History Output Request 32
3.14 Defining Surface 33
3.15 Interaction Properties 34
3.16 Defining Assignment 35
3.17 Predefined Field 35
3.18 Velocity Direction 36
3.19 Creating Mass 38
3.20 Defining Mass of Frame 38
3.21 Defining Mass of NGV 38
3.22 Creating Boundary Condition 39
3.23 Defining Barrier Boundary Condition 39
3.24 Defining Mesh Seed 40
3.25 Mesh Control Selection 41
3.26 Barrier Element Type 42
3.27 Frame Element Type 42
3.28 Mesh Instance 43
3.29 Simulation Result Visualization 43
4.1 Result View without NGV Tests 45
4.2 Deformed and Undeformed Mode 46
without NGV Tests
4.3 Graph of Force (N) Versus Time (Sec) 46
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4.4 Graph of Displacement (m) Versus Time (Sec) 47 without NGV Tests
4.5 Graph of Force (N) Versus Displacement (m) 48 without NGV Tests
4.6 Graph of Energy Changes (J) without NGV Tests 48
4.7 Result View with NGV Tests 50
4.8 Deformed and Undeformed Mode with NGV Tests 51
4.9 Graph of Force (N) Versus Time (Sec) 51
with NGV Tests
4.10 Graph of Displacement (m) Versus Time (Sec) 52 with NGV Tests
4.11 Graph of Force (N) Versus Displacement (m) 53 with NGV Tests
4.12 Graph of Energy Changes (J) with NGV Tests 53
4.13 Experimental Graph of Force versus Time 57
(Source: Japan Automobile Research Institute, (2003))
4.14 Energy Change in system 60
(Source: Europe Enhance Vehicle-Safety Committee, (1998))
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LIST OF SYMBOLS
mph = mile per hour
psi = pound per square inch
kg = kilogram
L = liter
F = force
m = mass
V = velocity
t = time
∆ V = velocity change
∆ t = time change
∆ P = momentum
I = impulse
mm = millimeter
M = meter
IX = moment inertia of X axis
Iy = moment inertia of Y axis
b = base
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LIST OF ABBREVIATIONS
MPV Multi-Purpose Vehicle NGV Natural Gas for Vehicle
IIHS Insurance Institute for Highway Safety FEA Finite Element Analysis
NHTSA National Highway Test Safety Association FHWA Federal Highway Association
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LIST OF APPENDICES
Appendix TITLE
1 Project Gantt chart
2 Sample of Calculation
3 Sample and Result Previous Research Crash Test in Different Weight of Vehicle
4 Guidelines for Rating Occupant Compartment Intrusion
5 NGV Reservoir Properties
6 Frontal Crash Test Result
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CHAPTER I
INTRODUCTION
1.1 General Overview
In the automotive manufacturing, the vehicle that was produced should be fulfill all the aspect and specific criteria including their design, performance and the most important is safety of the vehicle. In order to ensure the vehicle are suitable or 100% safe to drive, some test was applied to all model of vehicle including the mechanical test which is to ensure all the system involved in the vehicle can work properly or suitable to the vehicle. Besides that, the other important test will be discussed is crash test.
The crash test usually applied to the vehicle divided into 2 types which are frontal crash test and the side crash test. Besides, other test which has been considered to analyzed is oblique crash test and back crash test. There are 2 conditions that involve in the frontal crash such as full-width test and offset test. The purpose of these tests is to determine the condition of structure/safety cage of the vehicle, measure the injury of occupant and analyze restrains/dummy kinematics. The result of all these tests are different based on some factor such as acceleration and the weight of the vehicle tested.
The previous test on the previous model of vehicle shows that the vehicle passes or fulfills the entire standard that was needed in crash test with their standard
(21)
2 parameter of manufacturing. However, recently the new technology to reduce the usage of fuel was applied to the standard vehicle called NGV. The application of this system totally changes the standard manufacturing of the vehicle especially its maximum weight.
As we know, the different weight of vehicle will produce the different impact to the vehicle’s structure during crash. So, this project will show the frontal crash with full-width test on the vehicle from MPV model to overview their structure condition during crash.
1.2 Problem Statement
The application of NGV totally solves the problem of fuel price to the vehicle user. Unfortunately, the standard vehicle should make some modification to apply this NGV system. This application of the NGV to the vehicle will change the standard specification of the vehicle manufacturer’s especially their maximum vehicle’s weight. The previous analysis proved that the NGV system is safe to use in the normal and crash condition but did not mention about the impact of vehicle’s structure due to that crash after applied the NGV system.
As we know, the changes of vehicle weight will change a lot other physic character of vehicle such as their force and momentum. All of this has relationships that give an impact to the structure of vehicle especially during the crash. The impact produced may lead to vehicle’s structure damage and at the same time raised the high risk of injury or fatal death to the driver and passengers.
Hence, it is important to study the load analysis, energy absorption and its impact to the vehicle’s structure during crash due to the vehicle’s weight increase from the standard weight cause by application of the NGV system. This project will show the comparison of analysis and simulation on collision impact between the petrol and NGV as MPV that totally have a different weight.
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1.3 Objective
The objective of this project is to study, analyze and simulate impact during collisions of the multi-purpose vehicle (MPV) as NGV.
1.4 Scope
1. To do finite element analysis using ABAQUS software.
2. To do simulations on full-frontal collision of MPV compare petrol and NGV.
1.5 Planning of Research
This thesis is divided into five chapters which is introduction of the thesis has been covered in chapter 1. Besides, term as general overview, problem statement, objective and scope are also described. Consequently in chapter 2, the literature reviews of previous analysis on impact of collision in the different case and some information about the frontal crash and NGV system was shown. Meanwhile, explaining about the methodology; defining the frame design, creating the MPV frame, barrier structure and modeling the simulation was done in chapter 3. This thesis was continued with the chapter 4 which covered on result and the discussion. The analysis of the result that produced from the simulation done was describing details and completely discussion was done base on the recorded result. The comparison result between the MPV without NGV system and MPV with NGV system was explaining in this chapter as an objective of this thesis. Last but not list, the chapter 5 is a conclusion of this thesis. Some recommendation for the future research was included in this chapter.
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CHAPTER II
LITERATURE REVIEW
2.1 Vehicle Safety History
Over the past century, occupant safety has become an important design objective among all the performance criteria of ground transportation vehicles. Manufacturers realized early on the need to demonstrate occupant protection before the public accepted the automobile as a viable means of transportation. There are three distinct periods in the development history of automotive safety. An early period of safety from the turn of the century to 1935 was a period of genesis, growth, and developments to understanding the extremely complex process of vehicle collisions. The vehicle collision is a consequence of circumstances that produce abnormal operating conditions for the vehicle. Whether the collision occurs with another vehicle or with a stationary obstacle, it subjects the vehicle structure to forces and deformations. If the forces involved exceed the energy absorbing capability of the vehicle structure, occupants may be injured or killed.
This early period focused on basic improvements such as reduction of tire blowouts to avoid loss of vehicle control; introduction of the self-starter to eliminate injuries associated with engine cranking; incorporation of headlamps to provide for night visibility, installing laminated glass to reduce facial lacerations, and adopting an all-steel body structure for better occupant protection. In addition, the first full scales crash tests were conducted in the early 1930’s. These tests involved rollover simulations and car-to-barrier impact.
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The second period from 1936 to 1965 was an intermediate safety period. Early in this period, auto manufacturers introduced many crash avoidance devices including turn signals, dual windshield wipers, improved headlamps, a test to simulate head impact into the instrument panel, and high penetration-resistant windshield glass. In addition, General Motors conducted the first car-to-barrier frontal crash test, launching a vehicle into a retaining wall. These early tests were quite rudimentary by today standards. Neither dummies nor electronic instrumentation were sufficiently developed for use in crash testing. Evaluation of the vehicle structural performance was based on observations of the crushed vehicle. Perhaps the most significant safety device of that era was the introduction of seat belts as an option in 1956.
The third period starts in 1966, when President Lyndon Johnson signed into law the Highway Safety Act, and authorized the creation of the National Highway Traffic Safety Administration (NHTSA). During this post-regulation period, many mandatory safety standards, known as Federal Motor Vehicle Safety Standards (FMVSS), were introduced. These standards regulate several aspects of vehicle crashworthiness and crash avoidance performance.
Interestingly, long before 1966, occupant safety and security had been an integral part of the vehicle development process. Vehicle safety improvements over the past seven decades have focused on crash avoidance technology, structural crashworthiness, and occupant protection devices. The influence of the collective vehicle safety technologies, together with improvements to highways and better driver education has contributed to an impressive drop in the rate of traffic fatalities.
Today, transportation safety efforts focus on crashworthiness, crash avoidance, driver performance, and highway construction. Over the past decade automakers have added many features to help the driver avoid a crash, such as anti-lock braking systems, traction control devices and daytime running lamps. Vehicles also include many crashworthiness features such as rigid steel occupant-cells surrounded by strategically placed, energy absorbing components. In addition, vehicles are equipped with an impressive array of restraint systems such as energy-absorbing steering columns, three-point belts, front and side air bags and head
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LIST OF APPENDICES
Appendix TITLE
1 Project Gantt chart
2 Sample of Calculation
3 Sample and Result Previous Research Crash Test in Different Weight of Vehicle
4 Guidelines for Rating Occupant Compartment Intrusion
5 NGV Reservoir Properties
6 Frontal Crash Test Result
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CHAPTER I
INTRODUCTION
1.1 General Overview
In the automotive manufacturing, the vehicle that was produced should be fulfill all the aspect and specific criteria including their design, performance and the most important is safety of the vehicle. In order to ensure the vehicle are suitable or 100% safe to drive, some test was applied to all model of vehicle including the mechanical test which is to ensure all the system involved in the vehicle can work properly or suitable to the vehicle. Besides that, the other important test will be discussed is crash test.
The crash test usually applied to the vehicle divided into 2 types which are frontal crash test and the side crash test. Besides, other test which has been considered to analyzed is oblique crash test and back crash test. There are 2 conditions that involve in the frontal crash such as full-width test and offset test. The purpose of these tests is to determine the condition of structure/safety cage of the vehicle, measure the injury of occupant and analyze restrains/dummy kinematics. The result of all these tests are different based on some factor such as acceleration and the weight of the vehicle tested.
The previous test on the previous model of vehicle shows that the vehicle passes or fulfills the entire standard that was needed in crash test with their standard
(3)
parameter of manufacturing. However, recently the new technology to reduce the usage of fuel was applied to the standard vehicle called NGV. The application of this system totally changes the standard manufacturing of the vehicle especially its maximum weight.
As we know, the different weight of vehicle will produce the different impact to the vehicle’s structure during crash. So, this project will show the frontal crash with full-width test on the vehicle from MPV model to overview their structure condition during crash.
1.2 Problem Statement
The application of NGV totally solves the problem of fuel price to the vehicle user. Unfortunately, the standard vehicle should make some modification to apply this NGV system. This application of the NGV to the vehicle will change the standard specification of the vehicle manufacturer’s especially their maximum vehicle’s weight. The previous analysis proved that the NGV system is safe to use in the normal and crash condition but did not mention about the impact of vehicle’s structure due to that crash after applied the NGV system.
As we know, the changes of vehicle weight will change a lot other physic character of vehicle such as their force and momentum. All of this has relationships that give an impact to the structure of vehicle especially during the crash. The impact produced may lead to vehicle’s structure damage and at the same time raised the high risk of injury or fatal death to the driver and passengers.
Hence, it is important to study the load analysis, energy absorption and its impact to the vehicle’s structure during crash due to the vehicle’s weight increase from the standard weight cause by application of the NGV system. This project will show the comparison of analysis and simulation on collision impact between the petrol and NGV as MPV that totally have a different weight.
(4)
1.3 Objective
The objective of this project is to study, analyze and simulate impact during collisions of the multi-purpose vehicle (MPV) as NGV.
1.4 Scope
1. To do finite element analysis using ABAQUS software.
2. To do simulations on full-frontal collision of MPV compare petrol and NGV.
1.5 Planning of Research
This thesis is divided into five chapters which is introduction of the thesis has been covered in chapter 1. Besides, term as general overview, problem statement, objective and scope are also described. Consequently in chapter 2, the literature reviews of previous analysis on impact of collision in the different case and some information about the frontal crash and NGV system was shown. Meanwhile, explaining about the methodology; defining the frame design, creating the MPV frame, barrier structure and modeling the simulation was done in chapter 3. This thesis was continued with the chapter 4 which covered on result and the discussion. The analysis of the result that produced from the simulation done was describing details and completely discussion was done base on the recorded result. The comparison result between the MPV without NGV system and MPV with NGV system was explaining in this chapter as an objective of this thesis. Last but not list, the chapter 5 is a conclusion of this thesis. Some recommendation for the future research was included in this chapter.
(5)
CHAPTER II
LITERATURE REVIEW
2.1 Vehicle Safety History
Over the past century, occupant safety has become an important design objective among all the performance criteria of ground transportation vehicles. Manufacturers realized early on the need to demonstrate occupant protection before the public accepted the automobile as a viable means of transportation. There are three distinct periods in the development history of automotive safety. An early period of safety from the turn of the century to 1935 was a period of genesis, growth, and developments to understanding the extremely complex process of vehicle collisions. The vehicle collision is a consequence of circumstances that produce abnormal operating conditions for the vehicle. Whether the collision occurs with another vehicle or with a stationary obstacle, it subjects the vehicle structure to forces and deformations. If the forces involved exceed the energy absorbing capability of the vehicle structure, occupants may be injured or killed.
This early period focused on basic improvements such as reduction of tire blowouts to avoid loss of vehicle control; introduction of the self-starter to eliminate injuries associated with engine cranking; incorporation of headlamps to provide for night visibility, installing laminated glass to reduce facial lacerations, and adopting an all-steel body structure for better occupant protection. In addition, the first full scales crash tests were conducted in the early 1930’s. These tests involved rollover simulations and car-to-barrier impact.
(6)
The second period from 1936 to 1965 was an intermediate safety period. Early in this period, auto manufacturers introduced many crash avoidance devices including turn signals, dual windshield wipers, improved headlamps, a test to simulate head impact into the instrument panel, and high penetration-resistant windshield glass. In addition, General Motors conducted the first car-to-barrier frontal crash test, launching a vehicle into a retaining wall. These early tests were quite rudimentary by today standards. Neither dummies nor electronic instrumentation were sufficiently developed for use in crash testing. Evaluation of the vehicle structural performance was based on observations of the crushed vehicle. Perhaps the most significant safety device of that era was the introduction of seat belts as an option in 1956.
The third period starts in 1966, when President Lyndon Johnson signed into law the Highway Safety Act, and authorized the creation of the National Highway Traffic Safety Administration (NHTSA). During this post-regulation period, many mandatory safety standards, known as Federal Motor Vehicle Safety Standards (FMVSS), were introduced. These standards regulate several aspects of vehicle crashworthiness and crash avoidance performance.
Interestingly, long before 1966, occupant safety and security had been an integral part of the vehicle development process. Vehicle safety improvements over the past seven decades have focused on crash avoidance technology, structural crashworthiness, and occupant protection devices. The influence of the collective vehicle safety technologies, together with improvements to highways and better driver education has contributed to an impressive drop in the rate of traffic fatalities.
Today, transportation safety efforts focus on crashworthiness, crash avoidance, driver performance, and highway construction. Over the past decade automakers have added many features to help the driver avoid a crash, such as anti-lock braking systems, traction control devices and daytime running lamps. Vehicles also include many crashworthiness features such as rigid steel occupant-cells surrounded by strategically placed, energy absorbing components. In addition, vehicles are equipped with an impressive array of restraint systems such as energy-absorbing steering columns, three-point belts, front and side air bags and head