Khadilkar, M., "Development of Methodology to Perform Dual Side Roof Strength Analysis Using Virtual Tools," SAE Technical Paper 2014-01-0531, 2014, doi:10.4271/2014-01-0531.
The purpose of Federal Motor Vehicle Safety Standard 216 is to reduce fatalities and serious injuries when vehicle roof crushes into occupant compartment during rollover crash. Upgraded roof crush resistance standard (571.216a Standard No. 216a) requires vehicle to achieve maximum applied force of 3.0 times unloaded vehicle weight (UVW) on both driver and passenger sides of the roof. (For vehicles with gross vehicle weight rating ≤ 6,000 lb.)This paper provides an overview of current approach for dual side roof strength Finite Element Analysis (FEA) and its limitations. It also proposes a new approach based on powerful features available in virtual tools.In the current approach, passenger side loading follows driver side loading and requires two separate analyses before arriving at final assessment. In the proposed approach only one analysis suffices as driver and passenger side loadings are combined in a single analysis. This is achieved by using sensors to control loadings, resulting in reduced consumption of CPU time (for computer simulation) and disk space utilization without compromising accuracy of current approach.Commercial software LS-DYNA is used as FE solver to simulate dual side roof strength FE analysis with both the approaches for application of material, geometrical and contact nonlinearities.