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Development of Enhanced Honeycomb Barrier Finite Element Model for Rear Crash Simulations

Article of Honda R&D Technical Review Vol.21 No.1


This paper explains the development of an enhanced finite element barrier model for use in simulating the FMVSS 301 high speed rear crash test.
To create the barrier model, material testing was conducted on the aluminum honeycomb, cladding sheets, and adhesive which comprise the barrier. Particular emphasis was placed on the modeling of the aluminum honeycomb, which has been traditionally very challenging to model due to its highly anisotropic behavior. Recently developed modeling features were used to capture the complex behavior of the honeycomb material and extensive testing was conducted to define its behavior.
To validate the barrier model, a series of specification impact tests were conducted. These tests were chosen to represent the various load conditions the barrier might experience during crash testing. Each impact test was simulated and the barrier model was correlated to the test results.
Finally the barrier model was used in a full-vehicle crash simulation for verification. In this full-vehicle crash simulation, a significant improvement in the correlation of the model to test results was achieved. The results clearly indicate that improved predictive accuracy in crash test simulations can be obtained with the use of this new barrier model.


(1) United States Code of Federal Regulations, Title 49 -Transportation, Chapter V - National Highway Traffic Safety Administration, Department of Transportation, Subpart B - Federal Motor Vehicle Safety Standards, Section 571.301 - Standard Number 301; Fuel System Integrity. [49CFR571.301]
(2) Plascore Deformable Barrier, US (Federal) Side Impact FMVSS 214, www.plascore.com.
(3) Tryland, T.: Alternative Model of the Offset Deformable Barrier, 4th LS-DYNA Forum, Bamberg, paper B-II_33 (2005)
(4) Tryland, T.: Alternative Models of the Offset and Side Impact Deformable Barriers, Proceedings of the 9th International LS-DYNA Users Conference, paper 1-9 (2006)
(5) Kojima, S., Yasuki, T.: Development of Aluminum Honeycomb Model Using Shell Elements, Proceedings of the 9th International LS-DYNA Users Conference, paper 18-1 (2006)
(6) Kojima, S., Yasuki, T., Takatsudo, T.: A Study on Yielding Function of Aluminum Honeycomb, Proceedings of the 5th European LS-DYNA Users Conference, paper 5b-18 (2005)
(7) Hallquist, J. O.: LS-DYNA. Keyword User’s Manual, Vol. 2, p. 110-114. Livermore Software Technology Corporation (2007)

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