Vehicle crash can FEA model simulation and validation with experiment data

Vehicle crash-can transfers the kinetic energy into strain energy stored in the structure via a sequential deformation wall crushing process. The performance of the crash can FEA model and its ability of predicting mechanical behaviours in a crash event is assessed and verified via the FEA analysis and corresponding experiment data. Compression tests are performed to validate the FEA simulation results. Wall tolerance sensitivity is also investigated via FEA simulation in order to examine if and how the manufacturing defect could impose impact on crash can energy absorption capability. It is found that the performance of crash-can with manufacturing tolerances can be predicted by the FEA model derived in this paper. Internal energy analysis indicates the wall thickness is tolerance insensitive and manufacturing defect can be disregarded under the manufacturing tolerance standards.