DESIGN OF AN ENERGY

ABSORBER IN PP MATERIAL FOR

PEDESTRIAN PROTECTION
 A pillar Lower cad
Slider Tooling axis
Dog House with
Structural reinforcement

Main Tooling axis

Impact Position

2 way and 4 way Locator

MASTER SECTION
 FEA RESULTS
Static structural

MAX Equivalent stress = 4.29 MPa Total Deformation = 0.95mm

 Fatigue analysis

Life = 1e6 min Factor of safety = 11.58

Fatigue sensitivity
 Conclusion

 The total deformation in the A-pillar lower came to be 0.86 mm for 2.7mm thickness.
 The desired deformation was 5mm.
 So the part designed is safe
 The dog house was given a structural reinforcement to increase its rigidity.
 The ribs thickness was designed at 2mm that is 75% of the wall thickness to reduce the
sink marks.
 4 way and 2 way locators were used to restrict the 6 DOF of the part.
Steady state Thermal
Temperature profile along the thickness

Tmin = -34.64

Tmax = 81.72
Heat Flow = 121.5 W
 Thermal Behaviour at 80 Temp

MAX Equivalent stress = 29.34 MPa Total Deformation = 3.3mm

 Fatigue Analysis at 80 Temp

Life = 1.41e5 cycles Safety factor= 1.83

 Thermal Behaviour at -30 Temp

MAX Equivalent stress = 20.56 MPa Total Deformation = 2.95mm

 Fatigue Analysis at -30 Temp

Life = 1.88e5 cycles Safety factor= 2.04

 Fatigue sensitivity

80 o C -30 o C