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Nonlinear crash finite element analysis was performed to simulate the dynamic response of the instrument panel substrate in the head impact test. The finite element software used for this study was LS-DYNA3D. This paper describes the modeling strategy such as boundary conditions and loading condition. Energy absorption rate and deflection of the instrument panel substrate were investigated. The impact performance of various substrate designs were also simulated and compared with the baseline design. It was found that thinner substrate in the areas of impact can give substrate additional compliance which results in a greater crash energy absorption.

A process was developed and commercialized by Ford Motor Company, ACD for the recovery of S/MA-GR (glass fiber reinforced styrene maleic anhydride copolymer) resin from trim offal and rejected composite foam instrument panels, SAE# 93005. This high quality, low contaminate level “Reclaim”, S/MA-GR resin, has very good physical property retention through the manufacturing cycle. It compares favorably to post consumer “recycle” S/MA-GR resin recovered from Arizona. Acrylic (PMMA) resin recovered from manufacturing tail lamp lenses, etc. and post consumer applications was compounded with S/MA and fiberglass. This S/MA-GR compound has improved acrylic dispersion, uniform fiberglass content and improved mechanical properties: Dylark ® 378 P20A. The adverse effects of acrylic regrind on S/MA Boss/Joint Performance as described in SAE# 95810 should be minimized by reducing the variability incurred by blending regrind acrylic at the molding machine.