Design optimization of a B-pillar for crashworthiness of vehicle side impact

In this study, Hypermesh and Catia V5 software were adopted for finite element analysis (FEA) of a vehicle B-pillar. The design objectives were to optimise the B-Pillar such that the maximum displacement, weight, and maximum stress value of B-Pillar is minimised without compromising its yield strength and impact resistant properties. This is significant for the improvement of a vehicle's crashworthiness and ensuring the safety of passenger(s) during road accidents. This study initially analysed a given B-pillar design after being subjected to an even force of 140kN. The result produced von Mises stress of 1646MPa and deflection of 5.9mm. To ensure that EuroCAP directives were met, the B-Pillar was reinforced by adding extra steel plates to its inner surface and applying seam welding to ascertain their fusion and analysed using the same force of 140kN. Analysis of the reinforced B-Pillar design produced maximum von Mises stress of 673MPa with a maximum displacement value of 2.39mm. The optimised B-Pillar design was reinforced with 1.7kg steel plate with the overall mass of the B-Pillar amounting to 4.2kg of the total design compared to the original B-Pillar which had a total mass of 6kg. The optimised B-Pillar possessed less weight beside capable of resisting a force of 140kN with von Mises stress and displacement rate lower than the original B-Pillar. Thus, this indicates improvement in the tensile strength, stiffness, and impact resistant behaviour against collision forces by acting sideward on vehicles during road accidents. This can save such vehicles and passengers from severe damage that may result in loss of lives and properties. Hence, B-Pillar must be designed following the existing standards and tested before installation on vehicles to avoid unforeseen catastrophes.