Design and finite element analysis of vehicle safety parts suitable for roll forming

With this thesis, new sections were designed in the Catia program, in accordance with the roll-form production method, laser welding requirements, and within the determined design area for the bumper equipment in the crash management group located in the front of a class B vehicle. The crash performances of the new developed sections in the collision scenario with RCAR 15(+1/0) km/h speed, 40% offset and 10° angle rigid barrier were compared according to the benchmark product and the results were examined. Finite element analyzes were carried out in Ansys Mechanical APDL Product Launcher 2020 R1 program and Ls-dyna solver. Docol 1400 material was used as bumper material. Within the scope of the thesis, shock absorber crash boxes are used as the same shock absorbing structures in the benchmark product. In this study, the bumper specific energy value was increased by considering the acting force to the frame of vehicle and the displacement values in the direction of the impact axis.