This document summarizes a class seminar on car crash testing. It discusses how crash tests are conducted by driving vehicles into barriers at high speeds and using crash test dummies equipped with sensors. The standard types of crash tests are frontal, side impact, and offset tests. Safety systems like seatbelts and airbags help absorb the kinetic energy during impacts. Crash test ratings provide probabilities of injury based on test outcomes. While crash testing has improved safety, the document notes that mandatory crash testing and safety standards are still lacking in India.

1. CLASS SEMINAR ON CAR CRASH TESTING
CLASS SEMINAR REPORT
ON
“CAR CRASH TESTING”
BY
KUMAR MANIKANTAN T
01FM14EAT011
M TECH
1ST SEMESTER
AUTOMOTIVE TECHNOLOGY
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

2. CLASS SEMINAR ON CAR CRASH TESTING
Contents:
 Abstract.
 How car crash test works.
 Role of dummies and its instrumentations.
 Different Aspects of crash testing.
 Types of crash testing
 Safety systems.
 Absorption mechanism of crash energy.
 Crash test ratings.
 Indian scenario.
 Crash testing centres.
 Conclusion.
 Bibliography.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

3. CLASS SEMINAR ON CAR CRASH TESTING
ABSTRACT:
Driving a car is a high in itself, but safety is important too.
Choosing a safer car is very important to help prevent
crashes and accidents.
Thus, a thorough crash-testing program is critical for the
car makers and has contributed significantly to the
improving safety of cars.
According to the New Car Assessment Program (NCAP) of
National Highway Traffic Safety Administration (NHTSA)
cars made for model year 1997 and after must pass both the
tests frontal crash testing and side impact crash testing.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

4. CLASS SEMINAR ON CAR CRASH TESTING
HOW CRASH CAR TESTING WORKS:
Car to barrier impact
It is made to pull the vehicle with the wire and to run, and it
is made to collide with the barrier or the vehicle.
As the car crash test system, the one of a general method.
Car to car impact
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

5. CLASS SEMINAR ON CAR CRASH TESTING
Today, cars are much safer than they were some years back as
now there is a well-established testing program. Also the federal
law requires all cars to pass a 30-mile-per-hour frontal crash
test.
Crash test dummies are the key as they are used as replica for
man in a crash test. Dummies are made of materials that imitate
human physiology. Though dummies of different sizes are used,
dummy weighing 172 lbs (78 kg) and standing at 69 inches (5 ft.
9 inches or 1.75 m) tall is the most frequently used in testing.
Since 1997, GM's Hybrid III dummies became the industry
standard that complied with government regulations.
The dummy's job is to simulate a human being during a crash,
while collecting data that would not be possible to collect from a
human occupant. The dummies come in different sizes and they
are referred to by percentile and gender.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

6. CLASS SEMINAR ON CAR CRASH TESTING
A dummy is built from materials that mimic the physiology of
the human body. For example, it has a spine made from
alternating layers of metal discs and rubber pads
With the help of a number of specially built rigs, studies are
being conducted to discover what happens when parts of the
human body collide with parts of the interior or exterior of a car.
Crash test dummies are carefully calibrated and then positioned
in vehicles to mimic the movement of humans and record crash
forces during the tests. Each complex dummy includes 25 to 40
sensors to record the forces on various parts of the body.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

7. CLASS SEMINAR ON CAR CRASH TESTING
The dummies contain following three types of
instrumentation:
Accelerometers: - Measure the acceleration in a particular
direction. This data can be used to determine the probability of
injury. Inside the dummy's head, there is an accelerometer that
measures the acceleration in all three directions (fore-aft, up-down,
left-right). There are also accelerometers in the other
parts of the body
Load Sensors: - Inside the dummy are load sensors that
measure the amount of force on different body parts during a
crash. The maximum load in the bone can be used to determine
the probability of it breaking.
Movement Sensors: - These sensors are used in the dummy's
chest. They measure how much the chest deflects during a crash.
Before the crash-test dummies are placed in the vehicle,
researchers apply different colors of paint to the parts of the
dummies' bodies most likely to hit during a crash. The paint
marks in the car will indicate what part of the body hit what part
of the vehicle inside the cabin. This information helps
researchers develop improvements to prevent that type of injury
in future crashes
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

8. CLASS SEMINAR ON CAR CRASH TESTING
THE DIFFERENT ASPECTS OF THE CRASH
TESTING:
Infrastructure:
 A crash laboratory with an advanced high-tech crash
barrier.
 An outdoor test track that accommodates research for
different weather conditions
 Highly advanced crash simulator
 Lighting system which can provide up to 750,000 watts of
illumination without glare to film tests in slow motion. The
resulting pictures must be clear and dramatic.
 Equipment for advanced component testing.
 A supercomputer that crash tests non-existing cars.
 A system that propels vehicles to impact, accelerating full-size
pickups up to 50 mph.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

9. CLASS SEMINAR ON CAR CRASH TESTING
TYPES OF CRASH TESTS:
Simulating every accident type is impossible, which is why there
are number of standardized crash tests (which may resemble
most of the crashes that may take place) based on international
classifications and industry practices are used in the
development of the vehicle. This defines a repeatable way of
conducting crashes, so that improvements can be quantified and
modifications made. The three standard crash tests conducted
are:
1. Frontal Crash Test
2. Side Impact Test
3. Offset Crash Test
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

10. CLASS SEMINAR ON CAR CRASH TESTING
Frontal Crash Testing:
At 35 mph (56 kph) the car runs straight into a solid concrete
barrier. This is equivalent to a car moving at 35 mph hitting
another car of comparable weight moving at 35 mph. The
kinetic energy involved in the frontal crash test depends on the
speed and weight of the test vehicle. Full-width rigid-barrier
tests produce high occupant compartment decelerations, so
they're especially demanding of restraint systems. About 15
high-speed cameras will document the action shooting about
1,000 frames per second.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

11. CLASS SEMINAR ON CAR CRASH TESTING
Side Impact Crash Test :
In the side test a sled (of about 1,368-kg) with a deformable
"bumper" runs into the side of the test vehicle at around 31mph.
The test simulates a car that is crossing an intersection being
sides wiped by a car running a red light. Side impacts can be of
two types: - perpendicular impact and angled impact The
protection of occupants in side impacts is more important as the
space between the car’s body and the occupant is much less than
with the front and rear.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

12. CLASS SEMINAR ON CAR CRASH TESTING
Frontal Offset Crash Testing:
In offset tests, only one side of a vehicle's front end, not the full
width, hits the barrier so that a smaller area of the structure,
about 40% of the width of the front of the vehicle on the driver's
side must manage the crash energy. In the offset crash test the
vehicle is travels at 64kph (40mph) and collides with a crushable
aluminum barrier, which makes the forces in the test similar to
those involved in a frontal offset crash between two vehicles of
the same weight. The vehicle structure affects the outcome of an
offset frontal crash in two main ways: -absorption and
dissipation of crash energy and integrity of the passenger
compartment.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

13. CLASS SEMINAR ON CAR CRASH TESTING
How safety system works in crash test:
Though avoiding crash is the ideal situation it is not possible
always. So the best case scenario is the smoothest crash which
results in the survival of the person in the car. Absorbing the
kinetic energy that drops from a high speed to zero after the
crash is the key in this case. Safety systems must absorb this
kinetic energy as slowly and as evenly as possible to prevent
injuries. Seatbelt forms the first line of defense and removes
some of the impact. Then milliseconds later, to stop the force of
the seatbelt from becoming too high and thus hurtful, force
limiters in the seatbelt kick in. Then the airbag releases, and it
absorbs some more of the forward motion and prevents
occupants from slamming into a hard part of car. In this way all
the systems act together to minimize the kinetic energy.
The growth of technology and continuous researches on crash
testing are helping to make the accidents less fatal and save
thousands of lives
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

14. CLASS SEMINAR ON CAR CRASH TESTING
ABSORPTION MECHANISM OF CRASH
ENERGY:
 Obviously the ideal crash would be no crash at all. But, let's
assume you are going to crash, and that you want the best
possible chances of survival.
 Surviving a crash is all about kinetic energy. When the
body of occupant is moving (say at 35 mph), it has a certain
amount of kinetic energy. After the crash, when it comes to
a complete stop, it will have zero kinetic energy. To
minimize risk of injury, removing the kinetic energy as
slowly and evenly as possible is done by some of the
following safety systems in the car
 As soon as car hits the barrier the seatbelt can then absorb
some of your energy before the airbag deploys.
 Milliseconds later as the driver moves forward towards the
airbag, the force in the seatbelt holding him back would
start to hurt him, so the force limiters make sure that the
force in the seatbelts doesn't get too high.
 Next, the airbag deploys and absorbs some more of your
forward motion while protecting you from hitting anything
hard.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

15. CLASS SEMINAR ON CAR CRASH TESTING
 In a crash it is desirable that most of the crash energy is
absorbed and dissipated in the deformation of components
of each vehicle
 Crumple zones are vacant spaces in the front portion of the
car that act as cushions, where metal parts are supposed to
deform and absorb all the kinetic energy of the vehicle
 The engine on most cars is mounted so that in a crash, it is
forced backwards and downward so that it won't come into
the cabin and injure the occupant.
 Increasing the use of engine/suspension cradles allows
designers to better control this deformation and to by-pass
very rigid components such as engine blocks, which are not
effective energy absorbers.
 To avoid load concentrations it is important that the crash
forces are spread across the face of the deformable barrier.
 In a collision between two vehicles the occupants of the
heavier vehicle would generally be better off, due to the
physics of the collision. In the case of four-wheel-drive
vehicles colliding with passenger cars, however, this
advantage can be diminished by a stiff front structure.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

16. CLASS SEMINAR ON CAR CRASH TESTING
 Integrity of the passenger compartment should be
maintained in the crash test. The steering column, dash,
roof, roof pillars, pedals and floor panels should not be
pushed excessively inwards, where they are more likely to
injure the occupants.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

17. CLASS SEMINAR ON CAR CRASH TESTING
CRASH TEST RATINGS OF THE CARS:
RATING FOR FRONTAL IMPACT TESTS:
# Of stars Result
5 10% or lower chance of serious
injury
4 11% to 20% chance of serious
injury
3 21% to 35% chance of serious
injury
2 36% to 45% chance of serious
injury
1 46% or greater chance of serious
injury
RATING FOR SIDE IMPACT TESTS:
# Of
stars
Result
5 5% or lower chance of serious injury
4 6% to 10% chance of serious injury
3 11% to 20% chance of serious injury
2 21% to 25% chance of serious injury
1 26% or greater chance of serious
injury
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

18. CLASS SEMINAR ON CAR CRASH TESTING
Indian scenario:
India one of the biggest car market has the worst road safety
records in the world 1, 40,000 people die on roads every year
and close to 5 lakhs accidents.
According to recent test conducted on 5 of India’s most popular
cars from different manufacturer by Global NCAP and Institute
of road traffic education (IRT).
All the cars were tested on entry level variables only but there
was only a disturbing result.
Some cars even showed structural rigidity but anyhow failed the
test due to lack of Air bag as standard of safety.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

19. CLASS SEMINAR ON CAR CRASH TESTING
CRASH TESTING CENTERS:
 Throughout the world there are many institutes who crash
test vehicles, each organization’s test results are generally
for vehicles sold in its respective country or region.
 Insurance Institute for Highway Safety (IIHS- U.S)
http://www.hwysafety.org/vehicle_ratings/ratings.htm
 Euro NCAP: Established in 1997 and now backed by five
European Governments. www.euroncap.com
 New Car Assessment Japan: evaluates the safety of
automobiles currently on the Japanese market.
http://www.nasva.go.jp/english
 Australian NCAP (ANCAP): Australian New Car
Assessment Program (ANCAP) is supported by Australian
and New Zealan automobile clubs.
http://www.aaa.asn.au/ancap.htm
 India has centers for crash testing at the Automotive
Research Association of India (ARAI) and Society of
Indian Automobile Manufacturers (SIAM) in Bangalore.
 Tata Motors’s is the only car maker in India that has a
crash-test facility located at huge plant in Pune established
in 1996.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

20. CLASS SEMINAR ON CAR CRASH TESTING
CONCLUSION:
 The safety deficits of cars observed in accident statistics
can be alleviated if the structures of these cars are designed
and optimized for the situation they will most likely
encounter in a real world situation.
 One of the prime reasons for the alarming increase in
deaths due to accidents in India is that crash testing of
vehicles is not mandatory. Every carmaker emphasizes that
his make is better. But the consumer has to change his
approach and consider that car, which can best avoid
injuries to him in a crash.
 Crash testing leads to improvement of the safety systems.
These systems again have to be tested for their workability
during a crash. Hence crash testing plays a vital role in
continuous improvement of the safety systems.
 Design changes in vehicles like the crumple zones and the
location of engine block have been the results of evolution
of crash testing. Therefore in future, crash testing could
suggest many more design changes, which could further
minimize the probability of injury during a crash. Thus
crash testing make driving a more secure and reliable
experience.
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

21. CLASS SEMINAR ON CAR CRASH TESTING
Bibliography:
 Wikipedia.
 NDTV car n bike show.
 http://www.tata.com/tata_motors/articles/index.htm
 http://www.nhtsa.dot.gov/cars/testing/ncap/
 http://www.globalncap.com/indiancarcrash results
 Paper on Offset crash tests – Observations about vehicle
design and structural performance- by Michael Paine; Vehicle
Design and Research Pty Limited; Donald McGrane Crash
lab, NSW Roads and Traffic Authority; Jack Haley.
 Impact simulation and full scale crash testing of a low profile
concrete work zone barrier (Gary R. Consolazio *, Jae H.
Chung, Kurtis R. Gurley)
 Anthropomorphic Dummies for Crash andEscape System
Testing
(Mannequins anthropometriques utilizes lors des tests d'
impacted dejection)
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085

22. CLASS SEMINAR ON CAR CRASH TESTING
DEPT OF MECHANICAL ENGINEERING, PES UNIVERSITY, BANGALOR 560085