Crashworthiness analysis of vehicle side door support beams with different materials, thicknesses, and angles using the finite element method

Abstract Side door support beams are widely used to protect against side impacts, which are among the most critical threats to the safety of vehicle passengers. This study aimed to evaluate the crashworthiness of side door beams under Euro NCAP side pole impact conditions, considering three materials (aluminum alloy 6061-T6, aluminum alloy 5083-H116, A36 steel), three thicknesses (1.5, 2.0, 2.5 mm), and four beam angles (0°, 15°, 22.5°, 30°). Key crashworthiness parameters, including absorbed energy, specific energy absorption (SEA), reaction force, deformation characteristics, and velocity absorption time (VAT), were assessed. The results showed that the model designed with aluminum alloy 5083-H116, 15° beam angle, and 1.5 mm thickness achieved the highest SEA of 2.0043 kJ kg −1 , while the model defined with A36 steel, 0° beam angle, and 1.5 mm thickness achieved the maximum absorbed energy of 779.69 J. The reaction forces varied significantly between 20.6 kN (aluminum alloy 5083-H116, 0° beam angle, 1.5 mm thickness) and 30.5 kN (aluminum alloy 6061-T6, 30° beam angle, 2.5 mm thickness). Overall, the findings suggest that aluminum alloys, particularly aluminum alloy 5083-H116, are advantageous for lightweight crash-absorbing structures, while thickness optimization is necessary for balancing occupant protection and structural durability.