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Abstract
In recent times more emphasis has been given to passenger cars and small transport vehicles, but the safety features for
larger vehicles has always been a subject of secondary importance. Hence there exist a tremendous opportunity in improving
the safety levels of the passenger bus. There are many analysis done for rollover analysis, but the study of frontal impact
behavior of the passenger bus is completely ignored. Hence this project is carried out in this direction. This project work is
limited to the study of structural integrity during frontal impact and suggestion of some design changes in order to improve
safety.
In the current project work the study of frontal impact of a passenger bus has been done. The bus selected for this
purpose is a 54 seater bus from NEKRTC (branch of KSRTC), as the geometrical data of a passenger bus was provide by
KSRTC. Complete bus structure was modeled using ProE 2001 from the geometrical data collected from the coach building
company. Reverse engineering at certain locations was carried out in order to obtain the geometric data. Further the FE
modeling of the entire bus was carried using Hypermesh. Finally the simulation was carried out using commercially available
software LS Dyna.
From the analysis it was observed that the peak load acts on structural members, making them vulnerable to irregular
load distribution. This led to the implementation of crush initiators, which contributed in reduction of the peak load; thus
concluding with the importance of crush initiators in reducing the peak loads.
1. INTRODUCTION than 80% of drivers die than any other members of the bus.
Vehicle crashworthiness and occupant safety are the In frontal impact scenario more significance should be given
single most important areas of concerns in today’s on structural integrity, and hence this project work is carried
automotive industry. In earlier days the importance was out in this direction.
driven in the way of safety regulations, but nowadays for an The bus selected for crash analysis is a 54 seater bus
automotive company to survive in the market it is very from NEKRTC as shown in figure 1. North East Karnataka
essential to satisfy the safety expectations of the customers. Road Transport Corporation (NEKRTC) is the part of
Hence it is more of building a safer vehicle than that of the Karnataka State Road Transport Corporation (KSRTC)
competitor’s vehicle. In order to satisfy various safety catering to the transport needs of north eastern region of the
regulations, it is very important for the safety engineers to Karnataka state. As we have read in many newspapers and
perform various tests to evaluate the crashworthiness of the articles, where the accident rates due to state run buses are
vehicle, this is usually done in the beginning stages of the exorbitant, hence the bus selected in this project is NEKRTC
vehicle design and development. When it comes to safety bus.
concerns of vehicle crashworthiness, it is the area which
comes under passive safety. Due to advancement in the CAE
tools it is far easier in conducting the crash analysis, which
gives the results that are closely accurate with the physical
test setup. This has got many advantages like cost savings,
speed of analysis, accuracy of analysis and the ability of
performing various analysis with the same model
simultaneously. Thus most of the car manufacturers are able
to justify their product’s crashworthiness even before it is
actually manufactured.
In automotive world more emphasis has been given to
the safety of passenger cars, but seldom is the importance
given to the passenger bus. Hence in this project the
emphasis is towards the frontal impact behavior of a
passenger bus.
Figure 1. NEKRTC Bus
Among all the accidents that take place, frontal impact
has got the major share of 40%. Again in these conditions The coaches built for such buses are not designed with
the injury caused to drivers or the front passenger is various aspects of safety, neither driver nor passengers are
extremely high. Though the damage due to frontal impact of ensured with safety. There exists the tremendous
the bus is lesser when compared to other vehicles, but still opportunities in improving the safety features of this bus. As
the consequences of such impact on drivers are fatal. far as the safety is considered, only the structural safety can
According to the study during frontal impact of bus more be improved. It requires tremendous amount of
6. CONCLUSIONS
The study of frontal impact of a passenger bus has
suggested many key areas that have to be considered while
designing the structures of the bus. It was also studied for
some of the design changes that could help in improving
structure safety, although these suggestions are at very
nascent stage which needs much finer design refinement in
order to have an optimized solution. It was also evident that
the lack of professional approach towards bus body design
has contributed in unacceptable results during analysis,
which opens up the road towards consideration of many
design improvements. By non-linear analysis conducted on
Figure 21. Simulation of modified bus with crush bus, the following conclusions have been drawn up.
initiators • It has been understood that the load distribution on the
structures are not uniform, which lays down the road to
The load plot which shows the force vs time is as improvement in buckling characteristics of the
shown in figure 22. The important observation that has been structures.
made here is the peak load of 15.9 x 105 kN occurs at 0.06 • A redesign of left structural members is very essential,
seconds. The curve trend witnessed here clearly shows the because of the presence of door opening on this side the
time difference between buckling of various parts. It is also structure is very much weak and it requires proper
evident that the curve trend remains the same from the design in order to improve strength on this side. By
original design; this is because of the design change being doing this the load distribution can uniform on both the
done for only one structural member. The curve trend can sides and it also improves the overall behavior of the
change with more design modifications. bus during the frontal impact
• By having crush initiators, the peak load can be
reduced. This has been achieved by implementing such
designs to some of the structural members, which is
around 4% reduction in peak load. Although there is an
improvement in reducing the peak load, but a design
with much better analysis can improve the situation.
• Absence of structural members that are specifically
designed for absorbing high loads is evidently felt from
the analysis. By having such members the damage
caused to many other parts can be reduced and load
management can be in a much controlled manner.
• The design improvement that has been achieved is just
for few structural elements, if this approach is followed
Figure 22. Force vs Time plot
REFERENCES