Frontal impact on a coach, door sub-system numerical modelling

A coach is a heavy load vehicle used for long distances. It is a passenger transport defined as a M3 Class III vehicle. When developing new coach structures, the study of each sub-systems becomes fundamental in order to pre-validate the structure for improved driver and currier safety. In particular, a coach needs a careful study mainly due to the higher travelling speed. Currently there are few available standards to be followed. R-29 is the obligated regulation for trucks but it can also can be considered for a coach. Thus, when considering a frontal impact, the R-29 regulation must be followed. Since this study will be focused on the passenger door sub-system, it will be assumed that only 3% of the total impact energy from an external mass weighting 1500 kg will be transmitted to the door. It is expected that the coach front pillar will absorb the largest quantity of energy. The Finite Element Method (FEM) can be used to predict crash test results and improve the driver and currier safety. The Pam Crash FEM software, provided by ESI Group was used. This software is extensively used for crash simulation in the automotive industry. A dynamic study using the explicit method was performed. Belytschko-Tsay shell elements with reduced integration were used to construct the FEM mesh. The door is considered to be manufactured with three different materials. The tubular frame uses an S355 J2H steel alloy and the smaller components an EN 10130 DC01 steel alloy. The large frontal panel is manufactured in the EN AW 5754 H111 aluminium alloy.