Crash Structure Testing

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Bumpers
Vehicle doors

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Industry brochure: Automotive

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27.08.2020

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The deformation of body components when a force is applied is a key factor in the safety of vehicle occupants. Low-speed crash tests are therefore carried out on bodywork components and complete vehicle front ends before typical high-speed tests are performed. Even loads generated at low speeds provide relevant information, which is then channeled back into the design stage. In order to define the parameters for crash tests, static compression tests are performed under high loads so that damage initiation and propagation are detected.

Body Panel Testing

Body Panel Testing
Flexible clamping area for various body components

Flexible clamping area for various body components
Testing machine for low-speed crash tests

Testing machine for low-speed crash tests
Deformed crash structure

Deformed crash structure

Bumper Testing

This testing system is equipped with a large lower and smaller upper T-slotted mounting plate. Up to four load cells can be mounted flexibly on the lower plate, while three load cells can be attached to the upper plate. The four load cells are used to measure the axial force components of the attachment points of components. The total axial load can be measured by the three upper load cells, even if the component fails asymmetrically, thus resulting in a load applied eccentrically to the test axis. The example shows the load-deformation curve of bumpers being determined using this test setup.

Fender Testing⁽²⁾

Fender testing machine

Test arrangement with a modular single testing actuator .

Fender testing machine

Test arrangement with a modular single testing actuator .
Flexible deformation measurement

Deformation can be measured at different points with sensors.

Flexible deformation measurement

Deformation can be measured at different points with sensors.

Vehicle Door Testing

To determine the load-deformation curve of large body components (in this case a vehicle door), a widened version of a ZwickRoell materials testing machine with two load cells (the force components are totaled) and a semi-cylindrical bending tool is used. Since the components do not fail symmetrically along the length of the -flexure test tool, a bending moment arises relative to the test axis. This presents no difficulty from a measuring point of view since the two load cells used are insensitive to bending moments. The upper test area is equipped with specimen grips and an extensometer for standard tensile tests on metals.

Determination of strength values -TRUMPF relies on ZwickRoell Testing Laboratory

TRUMPF is the global market and technology leader in the field of industrial lasers and laser systems. TRUMPF lasers are used in virtually every industry, primarily for joining, cutting and marking and for surface processing on a wide range of materials. In a current project TRUMPF has been assisted by the ZwickRoell Testing Laboratory in determining the strength values of various joints for the manufacture of patchwork blanks used in automobile body construction.