Design And Analysis Of Car Side Door Impact Beam.

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DESIGN AND ANALYSIS OF CAR SIDE DOOR IMPACT BEAM

NUR EZRIN BINTI MAD SARIFF

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I admit that have read

this report and to my opinion this report

fulfill in terms of scope and quality for the Bachelor of Mechanical Engineering (Design & Innovation).

SIGNATURE :

NAME OF SUPERVISOR 1 :

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DESIGN AND ANALYSIS OF

CAR SIDE DOOR IMPACT BEAM

NUR EZRIN BINTI MAD SARIFF

This report is submitted in partial fulfillment of the requirements for the Bachelor of Mechanical Engineering (Design & Innovation)

Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka

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I hereby declare that this project report is written by me and is my own effort and that no part has been plagiarized without citations.

Signature :………

Name of writer : Nur Ezrin Bt. Mad Sariff

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iii

ACKNOWLEDGEMENT

Syukur Alhamdulillah and thanks to Allah, the Al-Mighty for giving me the patience and high confidence to complete this final year research project. I would like to take this opportunity to express my gratitude towards my supervisor, Mr. Fadzli Abdollah who was guiding me through completing the process. He was the one who not only motivated me but also gave me encouragement and some advises that helps me a lot during the research project.

The deepest appreciation to Mr. Shakir as a technician in Car Noise and Chasis Lab and Mr. Azhar Shah in Material Science Lab (FKP) in UTeM for letting me using the lab and providing me with all the equipments that I needed. And also special thanks to Mr. Tan Chi Seng as giving me permission to use his workshop in Malim Jaya for research purposes.

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ABSTRACT

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v

ABSTRAK

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TABLE OF CONTENTS

CHAPTER CONTENT PAGE

TITLE i

DECLARATION ii

ACKNOWLEDGEMENT iii

ABSTRACT iv deformation analysis due to bending as well as impact toughness.

2

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vii

way to use FEA software (ANSYS)

(c) Impact testing on aluminum alloy and carbon steel

2

2.2.1 Aluminum alloy characteristics

14

2.2.2 Types of aluminum alloy 15

2.2.3 6061T-6 Aluminum Alloy Properties

16

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2.5.1 Types of Impact Testing 27

2.5.1.1 Charpy Impact Test 27

2.5.1.2 Izod Impact Test 31

2.5.1.3 Gardner Weight Drop

Impact Test 3.1 Theoretical Analysis of Absorb Energy

using Bending Impact Formula

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ix

LIST OF TABLES

BIL TITLE PAGE

2.1 Characteristic of Aluminum Alloy

(Source:http://www1.eere.energy.gov/industry/alum inum/pdfs/autoroadmap.pdf)

14

2.2 Aluminum Alloy Mechanical Properties (6061T-6) (Source: Retrieved September 21, 2007, from http://www.simalex.com/material.htm#Aluminum% 20Mechanical%20Properties)

16

2.3 Aluminum Alloy Physical Properties (6061T-6) (Source: Retrieved September 21, 2007, from http://www.simalex.com/material.htm#Aluminum% 20Mechanical%20Properties)

17

2.4 Aluminum Alloy Physical Properties (6061T-6) (Source: Retrieved September 21, 2007, from http://www.simalex.com/material.htm#Aluminum% 20Mechanical%20Properties)

17

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4.1 Equivalent Static Force and Absorbed Energy for Different Types of Beam

49

4.2 Maximum Deflection and Load for Different Types of Beam

55

4.3 Impact Beam Weight 56

4.4 Impact Energy of Aluminum Alloy and High Strength Steel at Room Temperature

58

4.5 Influence of Temperature to The Absorbed Energy of Aluminum Alloy and High Strength Steel

59

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LIST OF FIGURES

2.1 Door Beam Construction

(Source: Retrieved July 25, 2007 from http://www..sussex.ac.uk/automotive/)

5

2.2 Rigidly Connected Beam

6

2.3 Geometric Restraints for Renault Twingo Door Model

6

2.4 Side-door impact beam with boundary conditions: (a) front side, (b) back side

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2.5 Circular Hollow area 8

2.6 Shaded area 8

2.7 Plain area 8

2.8 Square Hollow area 9

2.9 Shaded area 9

2.10 Plain area 10

2.11 I-type area 10

2.12 Plain area 10

2.13 Shaded area 11

2.14 C-type area 11

2.15 Plain area 12

2.16 Shaded area 12

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2.18 Impact Beam of Proton Wira 1.5 13

2.19 Bending on structural element 18

2.20 Bending deformation

(Source: Hibbeler, R. C. 2003)

19

2.21 Impact Beams

(Source: Retrieved July 16, 2007 from http://www.dwmic.co.kr)

19

2.22 Impact Beams in Side Door of Passenger Car (Source: Retrieved July 16, 2007 from http://www.dwmic.co.kr)

19

2.23 Shear and moment diagram 20

2.24 Applied force on beam 22

2.25 Maximum bending stress 24

2.26 Schematic Drawing of a standard impact-testing apparatus.

(Source: Smith, W. F. (2004). Foundations of materials science and engineering (3rd ed.). New York: Mc Graw Hill.)

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2.27 Effect of temperature on the energy absorbed upon impact by different types of materials.

(Source: Smith, W. F. (2004). Foundations of materials science and engineering (3rd ed.). New York: Mc Graw Hill.)

2.29 Lateral expansion of Charpy Impact specimen (Source:http://www.csun.edu/~tarek/EXP2%20Char py%20Impact.htm.)

30

2.30 TMI Impact Tester

(Source: http://www.ptli.com/default.asp.)

31

2.31 Gardner tester

(Source:http://www.instron.us/wa/home/default_en. aspx.)

31

3.1 Parameters for various cross sectional shape 33

3.2 Maximum bending stress. 34

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3.4 Beam Tool 36

3.5 Cross Section View (Square Hollow) 37

3.6 Cross Section View (Circular Hollow) 37

3.7 Cross Section View (I-type) 38

3.8 Cross Section View (C-type) 38

3.9 Nodes Created 39

3.10 Straight line 39

3.11 Element Length 40

3.12 Mesh Line 40

3.13 Load analysis 40

3.14 Displacement 41

3.15 Force 41

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3.17 Dimensions of Specimens 43

3.18 Charpy Impact Machine Specifications 44

3.19 Centering Tongs for V-Notch Charpy Specimens 45

4.1 Square Hollow Beam 50

4.2 Circular Hollow Beam 51

4.3 I-type Beam 52

4.4 C-type Beam 52

4.5 Deformation and Contour Plot (Aluminum Alloy) 54

4.6 Deformation and Contour Plot (High Strength Steel) 54

4.7 The Loads of Various Cross Section Shapes for Side Door Impact Beam

56

4.8 Absorbed Energy of Aluminum Alloy and High Strength Steel by using Charpy Impact Test

58

4.9 Effect of Temperature on The Energy Absorbed upon Impact by Different Types of Material.

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4.10 Fractures and Surface Contour of Specimens 60

4.11 Crack of specimens 62

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NHT = Non-Heat-Treatable

r = Radius

t = Thickness

V = Shear

v = Velocity

W = Width

wf = Final Lateral Dimension

wi = Initial Lateral Dimension

Δw = Lateral Expansion

x = x-axis

y = y-axis

Π = pi

σ = Stress

δ = Deformation/Deflection

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2.19 23

2.20 23

2.21 23

2.22 24

BIL PAGE

2.23 24

2.24 24

3.1 34

3.2 34

3.3 34

3.4 35

3.5 43

3.6 43

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LIST OF APPENDICES

BIL TITLE

A Deformation and Contour Plot for Circular Hollow, I-type and C-type

B Maximum Deflection for Different Types of Beam