Goals

The aim of this simulation is to see if the current side door can withstand the side collision described in the 2021 ASC regulations:

Geometry

Main focus is the door panel, and how to represent the connections between the door panel and the chassis.

NOTE: Simulation shouldn’t need the actual chassis file, however Solidworks assembly will have it at the moment.

Original:

Simplification:

With a collision on the door panel, the hinge arm will be pushed into contact with chassis beam
Simplified geometry, had to extend the width of the hinge arm to simplify assembly
NOTE: Hinge arm and base are connected by 1/4” pins, with collision most likely they will deform, hinges could potentially fail

Original:

Simplified:

In collision, latch striker rod will be in contact with latch body, for simplicity made as one part
In model, latch is held in place with 3D printed mount
- Thought that it would be useful in model, although not sure how to define in Ansys

Based on regs, a 5g load must be applied “in an area less than 100 mm high and less than 600 mm wide, with the bottom of the load 350 mm above the ground” in 3 areas
- To spread the load across as much of the door as possible, went for maximum possible area
- With wheels, should be 350mm above ground

Sets up model geometry and defines materials of components and composite stack-ups for door panel.

NOTE: Currently getting errors with ACP Setup

Haven’t got to this part due to issues with ACP-Pre, however, below are ideas of what I will be doing:

Set load solid with a 5g acceleration into the door panel
Fix faces of hinge and latch which are in contact with the chassis
- Back face of simplified hinge
- Cross section face of striker rod which is connected to chassis beam
Currently everything just has contact regions with each other, probably need to change