Abstract: Vehicle engine mounts have crucial influence on side rail deformation in frontal impact. In order to correctly predict the fracture failure behavior of engine mounts, a mechanical property test on cast aluminum material is conducted. Cast aluminum material card with failure criteria is set up based on CrachFEM tenacity failure criteria. Through the drop hammer test and simulation, the correctness of cast material card and the reliability of engine mounts modeling are verified. The results of vehicle crash simulation show that CrachFEM failure model can accurately simulate the fracture failure process of engine mounts, enable the deformation mode of side rail and the acceleration responses of car body closer to test results and enhance the accuracy of engine crash simulation, providing simulation assesement means for crashworthiness development.

Key words: cast aluminum mounts, crash failure prediction, CrachFEM failure model, simulation accuracy