Frontal Impact Test and Analysis on an Aluminum Front-End Structure

Abstract

A frontal impact test was performed on a front-end module consisting of 6xxx series aluminum extrusions, and some 5xxx series aluminum stampings as reinforcements. The front end structure consists mainly of a bumper, cross member, radiator support, front and backup lower rails, upper rails, and shock tower support. In addition to the main structure, a subframe containing the engine was also attached to the back-up rails. The front-end module was mounted on a sled at the upper and lower A-pillar points as well as at the back-up rail. In addition to measuring the barrier forces, load cells were located behind the main structural members to determine load transfer. The results of the tests showed progressive folding of the crush rails, and adequate absorption of the impact energy. To aid in the design, a CAE model of the front-end was created to determine the crash behavior of the structure during frontal impact. The final model, which took into account, the material properties of the weld joints showed good agreement with test results.