DESIGN OPTIMISATION OF OUTER HOOD PANELOF ESEMKA R2 CAR Design Optimisation Of Outer Hood Panel Of Esemka R2 Car To Improve Pedestrian Protection.

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i

DESIGN OPTIMISATION OF OUTER HOOD PANEL

OF ESEMKA R2 CAR

TO IMPROVE PEDESTRIAN PROTECTION

THESIS

Submitted to

Master Program of Mechanical Engineering

Postgraduated Program of Universitas Muhammadiyah Surakarta In fulfilment of the requirement for the degree of Master of Engineering

(Automotive Manufacture)

By

Binyamin

ID Number : U100 140 002

MASTER PROGRAM OF MECHANICAL ENGINEERING

POSTGRADUATE PROGRAM

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APPROVAL

Thesis report _{which tttled "DESIGN OPTIMISATION}

OF

OUTER HOOD

PANEL OF

ESEMKA

R2

CAR

TO

IMPROW

PEDESTRIAN PROTECTION', had been approved

by

Chair

of

Master Study Program

of

Mechanical Engineering In fulfilment of the requirement for the Master Degree

of

Engineering at Universitas Muhammadiyah Surakarta.

Prepared by:

Binyamin

Approved at:

Day

Date

:

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ID Number: U 100 140 002

Agus

llwi

Supervisor

;

Co-Supervisor

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Ilqtli

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Anggonor S.T., M.Eng., Ph.fD.

't'Marwan Effendy, S.T., M,T., Ph.D."

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NOTE OF ST}PERVISOR

Tri Widodo Besar Riyadi, S.T., M.Sc., Ph.D. Lecturer of Postgraduate Program

Universitas Muhammadiyah Strakarta

Official Note

Subject Thesis of Binyamin

Dear,

Chairman of Master Program of Mechanicel Engineering Universitas Muhammadiyah Surakarta

Assalamu'alaikum Warahmatultahi Wabarakaffi

After reading, researching, reviewing, correcting and make correction as needed to your thesis:

Name

: Binyamin ID

Number

: U 100 140 002

Program

: Master of Mechanical Engineering

Title

: Design Optimisation of Outer Hood Panel

of Esemka R2 Car to Improve Pedestian Protection

With this we can asisess the thesis can be approved for a thesis submitted in the

trial exam on Master of Mechanical Engineering

Wassalamu'alaikum Warahmatullahi Wabarakatuh

Surakarta,

I

October 2016 Supervisor

4

6-Tri Widodo Besar Riyadi, S.T., M.Sc., Ph.D.

aaa

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NOTE OFCO.SUPERVISOR

Agus Dwi Anggono, S.T., M"Eng., Ph.D.

Lecturer of Postgraduate Program [Jniversitas Muhammadiyah Strakarta

OfficialNote

Subject: Thesis of Binyamin

Dear,

Chaiman of Master Program of Mechanical Enginecring Universitrs Muhammadiyah Surakarta

Assalamu'alaikum Warahmatullahi r$/abarakatuh

After reading, researching, reviewing correcting and make correction as needed to your thesis:

Name

: Binyamin ID

Number

: U 100 140002

Program

: Master of Mechanical Engineering

Title

: Design Optimisation of Outer Hood Panel

of Esemka R2 Car to Improve Pedestrian Protection

With this we can assess the thesis can be approved for a thesis submitted in the

trial exarn on Master of Mechanical Engineering

Wassalamu'alaikum Waralrmatullahi Wabarakatuh

Srrakartq

(

October}Arc

Agus Dwi Anggono, S.T., M.EnB., Ph.D,

(5)

'- -=

APPROVAL OF THESIS FOR SUBMISSION

DESIGN OPTIItrSATION OF OUTER HOOD PANEL

OF ESEMKA R2 CAR TO IMPROYE PEDESTRIAN PROTECTION

submitted by

Binyamin

Has been examined by the board of examiners on 30th August 2016.4.11 feedback, corrections, and suggestions recommended by the examiners have been considered and

revision has been accordirlgly made by the student.

The boards of examiners,oortify

ilo,n.

A;ii3'is eligible for submission. ,t.'

$urak arta,3Oth September 2016 irector of Graduate School

m*"ffi-r'g.j

a

tm

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STATEMENT OF AUTHORSHIP

I

hereby confirm that ttre thesis entitled "Design Optimisation of Outer Hood

Panel of Esemka Rll Car to Improve Pedestrian Protection" is an original and autlrentic work written by myself and it has satisfied the rules and nogulations

of

Universitas Muhammadiyah Surakarta with respect to plagiarism. I certiS that all quotations and

the

sources

of

information have been

fully

referred and acknowledged accordingly.

Name

ID Number

Program

Field of study

Binyamin

u

100 140 002

Master of Mechanical Engineering

Automotive Manufacfure

I

confirm that this thesis has not been submiued for the award of any previous

degree in any tertiary institutions in Indonesia or abroad.

Stnakarta, B October

}Arc

fl

.ffi.

-:

@

Binyamin

a

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vii

ABSTRACT

Traffic accidents are terrible scourge that occur in many countries, specially for developing countries where transportation affairs like tangled yarn. Besides functioning as an engine compartment cover, the hood of modern compact SUV can also help to manage the impact energy of a pedestrian s head in a vehicle-pedestrian impact. This paper presents outer hood design of Esemka R2 that has a potential to improve hood s ability and also to absorb the impact energy of a pedestrian s head. The developed method for the design of an outer hood configuration aims to provide a robust design and homogeneous of Head Injury Criterion (HIC) for impact position at WAD 1000 and three different thicknesses (1.25 mm, 1.35 mm & 1.50 mm) of outer hood panel of Esemka R2 compact SUV, taking into consideration the limited space available for deformation. The non-linear Finite Element Analysis (FEA) software (Explicit Dynamics) was used in this research to simulate the testing procedurs of head impact for child pedestrian. The results show that the average of comparison dimensional of outer hood panel of Esemka R2 was 4.89 mm. The minimum of deformation space meet the requirement for HIC value which required to obtain robust and homogeneous head impact performance. Outer hood thickness and materials were identified as the factors to influence the stress and HIC value of the hood. By comparing all outer hood panels, aluminium alloy as the best selected material which has the lowest percentage value is 32.78% for the pedestrian protection.

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viii

ABSTRAKSI

Kecelakaan lalu lintas adalah momok yang mengerikan yang terjadi di banyak negara, khusus untuk negara-negara berkembang di mana urusan transportasi seperti benang kusut. Selain berfungsi sebagai penutup kompartemen mesin, kap SUV kompak yang modern juga dapat membantu untuk mengelola energi dampak kepala pejalan kaki di dampak kendaraan-pejalan kaki. makalah ini menyajikan desain kap luar Esemka R2 yang memiliki potensi untuk meningkatkan kemampuan hood dan juga untuk menyerap energi benturan kepala pejalan kaki ini. Metode yang dikembangkan untuk desain konfigurasi hood luar bertujuan untuk memberikan desain yang kuat dan homogen Head Injury Criterion(HIC) untuk posisi di WAD 1000 dan tiga ketebalan yang berbeda (1,25 mm, 1,35 mm & 1,50 mm) dari panel kap luar Esemka R2 kompak SUV, dengan mempertimbangkan ruang terbatas yang tersedia untuk deformasi. Software Non-linear

Analisis Elemen Hingga (Dynamics Explicit) yang digunakan dalam penelitian ini untuk mensimulasikan prosedur dasar pengujian impak kepala untuk pejalan kaki anak. Hasil penelitian menunjukkan bahwa rata-rata perbandingan dimensi panel kap luar Esemka R2 adalah 4,89 mm. Minimum ruang deformasi memenuhi persyaratan dengan nilai HIC yang homogen serta mendapatkan kinerja impak kepala yang aman. ketebalan hood luar dan bahan diidentifikasi sebagai faktor yang mempengaruhi stres dan nilai HIC pada kap. Dengan membandingkan semua panel kap luar, paduan aluminium sebagai bahan yang dipilih terbaik yang memiliki nilai persentase terendah adalah 32,78% untuk perlindungan pejalan kaki.

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ACKNOWLEDGMENT

Assalamu alaikum Warohmatullahi Wabarokatuh

Alhamdulillahirobbil alamiin.Praise and gratitude be to Allah SWT, The Lord of universe, because of His blessing and guidance the thesis can be done.

The thesis entitles Design Optimisation of Outer Hood Panel of Esemka R2 Car to Improve Pedestrian Protection can be done because of helping and supporting from other people. Therefore, the author sincerely would like to say thanks and appreciation to:

1. Prof. Bambang Setiaji as Rector of Universitas Muhammadiyah Surakarta.

2. Prof. Dr. Khudzaifah Dimyati as the Director of Postgraduate Program of Universitas Muhammadiyah Surakarta.

3. Marwan Effendy, S.T, M.T., Ph.D. as the Head of Master Program of Mechanical Engineering of Universitas Muhammadiyah Surakarta.

4. Tri Widodo Besar Riyadi, S.T., M.Sc., Ph.D.as the Supervisor who has given the researcher inspiration, spirit, advices, suggestions, and corrections to the thesis completion.

5. Agus Dwi Anggono, S.T., M.Eng., Ph.D. as the Co-supervisor who has given the researcher guidance, suggestions, and correction wisely.

6. All lectures of Master Program of Mechanical Engineering for the guidance during the study in the university.

7. Gatiningsih, SIP as head of postgraduate library who has given the facilities regarding literatures needs.

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9. SMK Warga Surakartaespecially forAutomotive Departmentthat had loaning Esemka R2 Car for supporting research.

10. His beloved Mother, poor Father, Brothers, Sisters, wife Aniq Hudiyah Bil Haq and daughter Syakira Alifa Rasyadani who always give enormous pray, biggest support, care, affection and great love.

11. His classmate friends Rahmadi, Wahyu, Puji, Amin Sulistyanto, Basuki Purwanto, Dhanar and Sanurya (Puput) thanks for your laugh, funnies experiences and supports, I will never forget you.

The author realizes that this thesis is far from being perfect, so the author sincerely welcomes any constructive comment, criticism, and suggestion from anyone. Moreover, the author expects that this thesis will become useful for the development of academic study and following research.

Wassalamu alaikum Warohmatullahi Wabarokatuh

Surakarta, October 2016 Author

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xi

LIST OF CONTENTS

THE TITLE OF THE RESEARCH... i

APPROVAL ... ii

NOTE OF SUPERVISOR ... iii

NOTE OF CO-SUPERVISOR ... iv

APPROVAL OF THESIS FOR SUBMISSION ... v

STATEMENT OF AUTHORSHIP ... vi

ABSTRACT ... vii

ABSTRAKSI... viii

ACKNOWLEDGEMENT ... ix

LIST OF CONTENTS ... xi

LIST OF FIGURES ... xiv

LIST OF TABLES ... xvi

NOMENCLATURE ... xvii

CHAPTER I INTRODUCTION ... 1

1.1 Background ... 1

1.2 Problem Statements... 3

1.3 Scope of Study ... 4

1.4 Objectives... 4

1.5 Contributions ... 4

1.6 Thesis Structure... 5

CHAPTER II LITERATURE REVIEW AND THEORY ... 6

2.1 Literature Review ... 6

2.2 Theory ... 11

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xii

2.2.2 Nodes... 13

2.2.3 Elements ... 16

2.2.4 FEM Application to Solid Mechanics Problems ... 17

2.2.5 Analysis for Three-Dimensional Problems... 18

2.2.6 Dynamics Equation of Motion ... 29

2.2.7 Triangular Membrane Element ... 33

2.2.8 Transformation Matrix ... 38

2.2.9 Consistent Load Vector ... 40

2.2.10 Head Injury Criterion (HIC) ... 42

2.3 Principle of Impulse and Momentum... 43

2.4 Impact... 45

2.4.1 Direct Central Impact ... 46

2.4.2 Oblique Central Impact ... 47

2.5 Reverse Engineering ... 50

2.5.1 Reverse Engineering of Machine ... 50

2.6 Regulatory vehicle design requirement for pedestrian protection ... 51

2.6.1 Global technical regulation (GTR-9) for pedestrian protection .. 51

2.6.2 EURO-NCAP (New Car Assessment Program)... 53

2.6.3 ANCAP (Australian New Car Assessment Program) ... 54

2.6.4 Kinematics of a pedestrian in an impact... 55

CHAPTER III METHODOLOGY ... 57

3.1 Research Location ... 57

3.2 Research Apparatus... 57

3.3 Procedure... 59

3.4 Dimensional Data Record ... 60

3.5 Modeling of Child Headfoam Impactor ... 61

3.5.1 Dimension... 61

3.5.2 Mass... 62

3.6 Parametric Geometric of Outer Hood Panel ... 62

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xiii

CHAPTER IV RESULTS AND DISCUSSION ... 66

4.1

Design Comparison of Outer Hood Panels of Esemka R2... 66

4.2 Deformation of Outer Hood Panel ... 67

4.3 Equivalent (Von-Misses) Stress ... 71

4.4 Headform Acceleration ... 73

CHAPTER V CONCLUSION AND RECOMMENDATION ... 77

5.1 Conclusion... 77

5.2 Recommendation... 77

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xiv

LIST OF FIGURES

Figure 1.1 Pedestrian unsafe condition ... 1

Figure 1.2 Unsafe pedestrians in Jakarta, Indonesia ... 2

Figure 2.1 Representation of a Milling Machine Structure by Finite Elements ... 12

Figure 2.2 Division of a domain into subdomains (elements) ... 13

Figure 2.3 DOF of One-Dimensional Element ... 14

Figure 2.4 DOF of Two-Dimensional Element ... 15

Figure 2.5 Local and Global DOF of Three-Dimensional Element ... 15

Figure 2.6 Description of line, area, and volume elements with node numbers at the element level ... 16

Figure 2.7 Discretization of a domain: element and node numbering ... 17

Figure 2.8 A Tetrahedron Element in Global xyz System ... 19

Figure 2.9 A Hexahedron Element with Eight Nodes ... 23

Figure 2.10 Load Acting on a Plate ... 34

Figure 2.11 Local and Global Coordinates ... 38

Figure 2.12 Principle of Impulse and Momentum ... 44

Figure 2.13 Central Impact of Particles ... 45

Figure 2.14 Particles of Direct Central Impact ... 46

Figure 2.15 Period of Deformation and Restitution... 47

Figure 2.16 Particles at Oblique Central Impact ... 48

Figure 2.17 Particles at Oblique Central Impact along thenaxis... 48

Figure 2.18 Oblique Central Impact between Ball and Block ... 49

Figure 2.19 Period of Momentum Between Ball and Block ... 50

Figure 2.20 GTR-9 pedestrian protection head impact requirements ... 51

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xv

Figure 2.22 Wrap Around Distances (WAD)... 53

Figure 2.23 Head Impact location (left) and leg impact location (right) ... 54

Figure 2.24 ANCAP pedestrian protection impact requirements ... 55

Figure 2.25 Kinematics of a pedestrian in PPCFC... 56

Figure 2.26 Pedestrian subsystem impactors and their relation to a struck pedestrian ... 56

Figure 3.1 Side view of Esemka Rajawali 2 SUV ... 57

Figure 3.2 Manual CMM ... 58

Figure 3.3 ASUS Laptop A455L Series... 58

Figure 3.4 Design of CMM Manual in Solidwoks... 60

Figure 3.5 Activity of Dimensional Data Record ... 60

Figure 3.6 3-Dimensional Shape of Child Headform Impactor ... 61

Figure 3.7 Detail of Child Headfoam Impactor ... 61

Figure 3.8 Coordinates Design Boundary of Bonnet ... 62

Figure 3.9 Boundary-Surface Generation of Bonnet ... 63

Figure 3.10 Finite Element of Design Models ... 64

Figure 3.11 Boundary Condition of The Outer Hood Panel and Headform .. 64

Figure 4.1 Design Comparison of Outer Hood Panel of Esemka R2... 66

Figure 4.2 Deformation pattern of outer hood panel of aluminum alloy (1.25 mm) at different time in FE models ... 68

Figure 4.3 Comparison of outer hood panel deformation vs. time of three difference materials with 1.25 mm, 1.35 mm and 1.50 mm thicknesses ... 70

Figure 4.4 Equivalent (von-misses) stress of outer hood panel of aluminum alloy (1.25 mm) at different time in FE models ... 71

Figure 4.5 Comparison of equivalent stress vs. time of three difference materials with 1.25 mm, 1.35 mm and 1.50 mm thicknesses ... 72

Figure 4.6 Headform acceleration on outer hood panel of aluminum alloy (1.25 mm) in FE model at different time ... 74

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xvi

LIST OF TABLES

Table 2.1 Degrees of freedom and force vectors in FEA for different

engineering disciplines ... 14 Table 2.2 Description of numbering at the element level ... 17 Table 2.3 Comparison between type of equations and number of equations

based on dimensional problems ... 18 Table 2.4 The unknown qua ntities, whose number is equal to the number

of equations available, in various problems are given below ... 18 Table 4.1 Dimensional Comparison of Outer Hood Panel of Esemka R2 .... 67 Table 4.2 The maximum deformation of outer hood panels in the collision

with child headform impactor ... 70 Table 4.3 The maximum stress of outer hood panelsin the collision with

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xvii

NOMENCLATURE

Resultant acceleration (g)

A Area (m2)

t1, t2 Two time instants (s)

E Young s modulus (GPa) F Force (N)

Fx Force at x component (N)

Fy Force at y component (N)

Fz Force at z component (N)

m Mass of the head impactor (kg) mA Mass of particle A (kg)

mB Mass of particle B (kg)

Density (Kg/m3)

v Velocity of the head impactor (m/s) Velocity at x component (m/s) Velocity at y component (m/s) Velocity at z component (m/s) Initial velocity (m/s)

Final velocity (m/s)

Initial velocity of particle A (m/s) Initial velocity of particle B (m/s) Final velocity of particle A (m/s) Final velocity of particle B (m/s) Imp Impuls (N.s)

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xviii

R Force whichduring the period of restitution (N) Angle (°)

L Lagrangian function Damping coefficient

( ) _{Kinetic energy of element} ( ) _{Dissipation function of element} ( ) _{Potential energy of element} ( ) _{Element surface}

( ) _{Element volume}

Nodal displacemen

̇ Nodal velocity

⃗( ) _{Vector of nodal displacements}

⃗̇ ( ) _{Vector of nodal velocities}

⃗̈ Vector of nodal accelerations in the global system

u, v, w Displacement components

, , Components of the global coordinates

⃗ Vector of displacements

⃗̇ Vector of velocities of element

( ) _{Mass matrix of the element (in the global system)}

( ) _{Stiffness matrix of the element (in the global system)}

( )

Stiffness matrix of element due to shear stresses

( )

Stiffness matrix of element due to normal stresses

( ) _{Damping matrix of the element (in the global system)}

[ ] Master mass matrix of the structure

[ ] Master stiffness matrix of the structure

[ ] Master damping matrix of the structure

⃗( ) Vector of element nodal forces produced by surface forces

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xix ⃗ Stress vector

⃗ Three-dimensional strain displacement vector [N] Shape function of the element matrix

[B] Matrix that relates the strains to the nodal displacement [D] Elasticity matrix

[ ] Transformation matrix

( ) _{Element volume}

⃗( ) _{The total load vector due to initial (thermal) strains}