Developing a crashworthy seating system to various European and worldwide standards usually involves a high number of physical tests that are time consuming and costly. By applying advanced finite element analysis (FEA) with fully representative instrumentation and dummy models, the rail seat design can be optimised to meet performance targets and eliminate prototype testing altogether. In this paper a case study is presented in which a novel seat concept is developed to crashworthiness requirements using FEA. This approach is validated by the close correlation of test and simulation results. The latest European crashworthiness requirements for rail seat systems are introduced along with a novel lightweight seat concept The FE process and methodology is presented along with some of the assumptions that must be taken into consideration for virtual testing of such a product undergoing a high speed impact By replicating the physical test set up including correct dummy positioning and using a real world sled pulse curve as a prescribed motion, the FE model gave representative results that enabled the seat design to be optimised prior to any materials being ordered or tools manufactured thus eliminating a complete prototype testing phase altogether. Once satisfactory resuäs were achieved with the FE model, a prototype seat was manufactured and physical testing took place at MIFlAs Hyge reverse accelerator facility. The tests were fully instrumented and equipped wäh anthropomorphic test devices (ATDs). This enabled the FE model to be validated through a variety of metrics and injury criteria as defined by the crashworthiness standards. Once close correlation was achieved, a further phase of cost and weight optimisation was conducted using the validated model wäh high accuracy and reliability. A second phase of physical testing was conducted for compliance and certification purposes and showed very close results to the simulations proving the validity of the method and showing potential for even greater cost reductions for future projects.
Developing a crashworthy rail seating system using finite element analysis
2013
10 Seiten, 2 Bilder, 2 Tabellen, 3 Quellen
Aufsatz (Konferenz)
Englisch
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