Material performance analysis in frontal collision simulation of electric vehicle frames using explicit dynamic finite element analysis method

Crash testing, a crucial method for evaluating the strength of vehicle frame structures, plays a significant role in developing safer designs. This approach enables manufacturers to identify necessary design improvements by analyzing the performance of materials and structures. Material reliability enhances passenger safety and minimizes losses from structural failure under operational loads. While extensive research has been conducted on crash testing for passenger cars, limited studies have focused on comparing different materials for vehicle frames. Addressing this gap, this study compares two materials, carbon steel (ASTM A36) and high-strength aluminum alloy (Al-7075T6), to assess passenger safety during a collision. The study uses Finite Element Analysis (FEA) with ANSYS software to simulate crashes. The results indicate that ASTM A36 exhibits higher stress values and lower safety factors, making it more vulnerable to permanent deformation and structural failure. In contrast, Al-7075T6 absorbs impact more effectively with a lower stress value and higher safety factor, making it the superior choice for electric vehicle frames. This material enhances safety and contributes to weight reduction, improving energy efficiency. Future research will focus on optimizing structural design to minimize deformation and stress while improving the safety factor, particularly in high-stress bending areas.