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The effect of epoxy-based structural foam on strength, stiffness, and energy absorption of foam filled structural components is investigated and implemented to formulate design guide-lines that can be used in enhancing weight reduction and engineering functions of systems. An experimental approach is first utilized to identify design variables such as foam density, gage, and foam layer thickness, that are needed to enhance the weight/ performance ratio of structural hat-section components. A CAE approach using non-linear, large deformation finite element analysis is used to model the hat-section components. An acceptance level of confidence in the CAE analytical tools is then established based on comparisons of results between the two approaches. Upon that, the CAE analytical tools are deployed in a sensitivity study to quantify the crush/crash characteristics of foam-filled hat-section components with respect to the changes in the afore mentioned design variables.

The effect of polyurethane structural foam on strength, stiffness, and energy absorption of foam filled structural components is investigated to formulate design directions that may be used in weight reduction and engineering functions of vehicle systems. An experimental/testing approach is first utilized using Taguchi’s DOE to identify design variables [foam density, gage, and material type], that are needed to determine the weight/performance ratio of structural hat-section components. An analytical CAE approach is then used to analyze the hat-section components using non-linear, large deformation finite element analysis. An accepted level of confidence in the CAE analytical tools is then established based on comparison of results between the two approaches.

Statistic shows the majority of real world frontal collisions involve only partial overlap of the vehicle front end. Thus the European Experimental Vehicle Committee (EEVC) has established a safety standard and test procedure utilizing a deformable barrier for offset impacts. The offset deformable barrier (ODB) is designed to represent the characteristics of a vehicle front end. Therefore, it can replace a target vehicle and the offset test can be conducted economically. Many component, sub-assembly and full vehicle system tests have been conducted in Ford using the EEVC ODB. Based on the various tests, the barrier responds differently depending on the front end design and the size of an impacting vehicle. Sometimes the front end of a test vehicle punches through the barrier. Also rupture of aluminum sheets and tearing of honeycomb materials are often observed in post-test barriers.