You are on page 1of 3

IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm


Email: editoriijme@ipasj.org
ISSN 2321-6441

A Publisher for Research Motivation........

Volume 2, Issue 11, November 2014

Manufacturing an Impact Attenuator for


Formula Prototype Cars
Mr. Akash Sengupta1, Mr. Apurba Sharma2 and Mr. Amritabha Chakraborty3
1

Mr. Akash Sengupta, 2 Mr. Apurba Sharma, Former Student, Department of Automobile Engineering, MCKV Institute
of Engineering, Liluah, Howrah, West Bengal

Mr. Amritabha Chakraborty, Department of Mechanical Engineering, MCKV Institute of Engineering, Liluah, Howrah,
West Bengal

ABSTRACT
The paper aims to design and manufacture an Impact Attenuator for a formula prototype car. The design has been done using
CATIA V5R20 and was analysed in ANSYS 13.0. Post manufacturing testing has been done to validate the simulation data.

Keywords:- Impact Attenuator,

1. INTRODUCTION
The Impact Attenuator is an energy absorber device. Its purpose is to absorb as much energy as possible in case of
collision. It provides a load path for transverse and vertical loads in the event of off-centered and off-axis impacts. The
safety of driver during an accident depends on this hence no mistake can be afforded while manufacturing or designing
this thing. Also, it must be easy to install so that the weekend autocross driver can himself only attach it without the
need of skilled expertise.

2. THE DESIGN CONSIDERATION


The design of this device requires consideration of the followings engineering metrics:
1. Low weight
2. Small size
3. Fire resistant
4. Cost
5. Energy absorption capability

3. DESIGN AND ANALYSIS


3.1 CAD Modeling
The requirements and specifications of the Impact Attenuator [1] can be summarized as:
1. It must be attached securely to the front bulkhead of the car
2. It must be able to absorb an impact of a 300 kg mass at 7 m/s with a deceleration less than 20 G
3. It must have a minimum size of 100 mm high, 200 mm wide and 150 mm long
The design of the impact attenuator has been made by setting up constrains in a chronological order. The first and the
most important constrain was the drivers safety and effective use of the device in case of a collision. Then the next
constrain of installing the attenuator without a skilled person came. So the CAD Model is built as shown in Figure 1
and Figure 2. Figure 3 shows how will it look with the chassis of the formula type car.

Figure 1: Isometric View

Volume 2, Issue 11, November 2014

Figure 2: Side View

Page 11

IPASJ International Journal of Mechanical Engineering (IIJME)


A Publisher for Research Motivation........

Volume 2, Issue 11, November 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm


Email: editoriijme@ipasj.org
ISSN 2321-6441

Figure 3: Impact attenuator with chassis


3.2 Analysis
A test has also been performed in ANSYS software for the impact attenuator of the car. The impact attenuator as
designed to be completely made of aluminium sheets is fed with load as calculated from the required data given in the
rule book. After the test, it is seen that the attenuator will absorb most of the impact leaving the driver unharmed. The
maximum deceleration is 17 g as against 20 g allowed

Figure 4: Analysis

4. Manufacturing and Testing


Manufacturing the attenuator to specifications is a big task but with proper equipments and a good jig makes the
process easy. The Attenuator is made using 2mm Aluminum sheets welded together. It also consists of an AntiIntrusion plate made of solid steel of 1.5mm. The requirement is always that the anti- intrusion plate does not deflect
more than 1 inch. Figure 5 shows the deflection before and Figure 6 shows the test in mid-way. Figure 7 shows the
attenuator after test.

Figure 5: Before crushing

Volume 2, Issue 11, November 2014

Page 12

IPASJ International Journal of Mechanical Engineering (IIJME)


A Publisher for Research Motivation........

Volume 2, Issue 11, November 2014

Web Site: http://www.ipasj.org/IIJME/IIJME.htm


Email: editoriijme@ipasj.org
ISSN 2321-6441

Figure 6: Analysis Midway

References
[1] Automobile Engineering (RB Gupta)
[2] Supra SAE India Rulebook 2014

AUTHOR
Akash Sen Gupta received the B.Tech degree in Automobile Engineering from West Bengal University of
Technology(MCKV Institute Of Engineering) in 2014.

Apurba Sharma received the B.Tech degree in Automobile Engineering from West Bengal University of
Technology(MCKV Institute Of Engineering) in 2014.

Amritabha Chakroborty is undergoing his B.Tech degree in Mechanichal Engineering from West Bengal
University of Technology (MCKV Institute Of Engineering) in 2014.

Volume 2, Issue 11, November 2014

Page 13

You might also like