Die Cast Front Side Member Rib Height Control
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Solution Overview
Problem
Existing front side members in vehicles suffer from incomplete crushing during collisions, leading to reduced energy absorption efficiency and potential incomplete energy absorption, due to the deformation of chambers and accumulation of fragments, which can also result in excessive crushing loads if hollowed-out portions are eliminated.
Innovation Solution
A front side member with an open cross-sectional shape, integrally molded by die casting, featuring ribs that connect opposite surfaces and a minimum rib height equal to or greater than half the width dimension of the walls, controlling the hollowing-out amount to prevent fragment accumulation and ensure intended energy absorption, with the rib height increasing towards the rear to facilitate easier crushing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hollowed-out portions are provided in ribs to reduce crushing load, then energy absorption amount is improved, but incomplete crushing occurs causing fragments to remain and energy absorption efficiency to decrease
Solution Approach 1:
The patent changes the geometric parameters of the ribs by setting the minimum rib height to be equal to or greater than half the width direction dimension of the upper and lower walls. This parameter adjustment prevents incomplete crushing and fragment accumulation while maintaining adequate energy absorption capacity through controlled deformation patterns.
Solution Approach 2:
Instead of hollowing out the ribs to reduce crushing load, the patent inverts the approach by ensuring sufficient rib height (solid structure) to prevent incomplete crushing. The design accepts higher crushing loads in exchange for reliable complete crushing and fragment-free deformation, thereby maintaining energy absorption efficiency.
2Reliability
If hollowed-out portions are eliminated to suppress incomplete crushing, then energy absorption efficiency is improved, but crushing load becomes too large and intended energy absorption amount cannot be secured
Solution Approach 1:
The patent optimizes the rib height parameter to be equal to or greater than half the width direction dimension of the walls, which balances the crushing load and energy absorption capacity. This parameter setting prevents incomplete crushing while maintaining manageable crushing loads through controlled deformation mechanisms.
3Stability of the object's composition
If rib height is increased to prevent incomplete crushing, then deformation robustness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent sets the minimum rib height to be equal to or greater than half the width direction dimension of the walls, which provides sufficient deformation robustness while maintaining manufacturability. This parameter choice avoids excessive structural complexity by using a simple proportional relationship rather than complex variable geometry.
Data Source
AI summary
A front side member extends in a vehicle front-rear direction at each of both left and right sides in a vehicle width direction, has an open cross-sectional shape in which an opening is provided at at least one side thereof in the vehicle width direction, and is integrally molded by die casting. The front side member includes plural ribs that connect a bottom surface at a side opposite from the opening, a lower surface of an upper wall in a vehicle up-down direction, and an upper surface of a lower wall in the vehicle up-down direction. A minimum rib height of the ribs along the vehicle width direction is set to be equal to or greater than half of a width direction dimension D of the upper wall and the lower wall.