Closed Beam Notch Pattern for Controlled Impact Fracture
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Solution Overview
Problem
The challenge in automotive design is controlling the impact response and fracture behavior of thin metal parts, particularly in sheet metal components, which leads to variable results in component testing and makes correlation with simulation models challenging.
Innovation Solution
A closed beam assembly with a hat-shaped member and a notched pattern is designed to systematically control material fracture by defining specific apertures in the raised wall portion, allowing for predictable failure under impact loads, and is validated using an elliptical impactor to map failure initiation and propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional component testing is used for sheet metal materials, then the testing can be performed with standard setups, but the fracture behavior becomes difficult to control and results become highly variable
Solution Approach 1:
The patent applies preliminary action by pre-defining notched patterns in the raised wall portion of the hat-shaped member before impact testing. These notches are strategically positioned to control where fracture will initiate and propagate, ensuring consistent and predictable fracture behavior across multiple tests. The notched pattern serves as a pre-planned failure path that guides the fracture process rather than allowing random buckling modes.
2Measurement precision
If standard impact testing is used on thin metal parts, then the testing procedure remains simple, but the fracture mode becomes unpredictable with highly variable responses
Solution Approach 1:
The patent applies local quality by modifying only the specific region where fracture control is needed - the raised wall portion of the hat-shaped member. The notched pattern is localized to this area, creating controlled stress concentration points that dictate fracture initiation. The rest of the structure remains unchanged, maintaining overall structural integrity while achieving precise fracture control at the critical location.
3Reliability
If unmodified hat-shaped members are used in impact testing, then the structural integrity is maintained, but the fracture behavior is difficult to control for validation purposes
Solution Approach 1:
The notched pattern is designed and positioned in advance based on simulation predictions and engineering judgment. This preliminary design of the fracture path allows for reliable correlation between physical testing and computer-aided engineering simulations, as the fracture will occur at predictable locations that can be pre-modeled in the simulation software.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise control of material fracture, enhancing the correlation between experimental results and computer-aided engineering simulations, thereby improving the predictive accuracy of vehicle design models.
Implementation Method 1
a notched pattern defined in the raised wall portion of the hat-shaped member for controlled material fracture when the hat-shaped member is subjected to an impact load
Data Source
AI summary
A closed beam assembly and method for controlled material fracture thereof for a vehicle includes a hat-shaped member having a raised wall portion, supporting sidewall portions spaced apart from one another and depending from the raised wall portion, and flange wall portions extending outwardly from distal ends of the supporting sidewall portions. The closed beam assembly further includes a flat member mated with the flange wall portions to define a closed cross-section and a notched pattern defined in the raised wall portion of the hat-shaped member for controlled material fracture when the hat-shaped member is subjected to an impact load.