Metodik för krocksimulering av ryggstöd på truck : En jämförelse mellan de två lösarna OptiStruct och RADIOSS

Toyota Material Handling is evaluating the feasibility of adding a backrest to one of its pallet trucks to improve driver safety when reversing and for ergonomic benefits. According to standards, the backrest must withstand certain permanent deformation when colliding with a beam rack at 1.6 km/h. To minimize costs, reduce time, minimize environmental impact, and mitigate safety risks, this study investigates a virtual methodology for crash testing. The aim is to develop a suitable material model for the backrest and evaluate which of the two solvers, OptiStruct and RADIOSS, is most ideal for a crash simulation. A physical bending test is conducted, and the data is used to calibrate a Johnson-Cook material model. The backrest is then simulated in three increasingly complex finite element models (simple, semi, and advanced), and results are compared to physical tests for validation. Finally, the calibrated models are used to simulate the forklift colliding with a beam rack, and this is evaluated against an existing physical pendulum test. Both solvers are comparable in usability, but the advanced model with the Johnson-Cook material model, solved using RADIOSS, offers results closest to the physical pendulum test. However, significant deviations in permanent deformation remain, and possible error sources are discussed.