SteelStructure DamageAnalysis Textbook Version:13.3 ©2011-2013Inter-IndustryConferenceonAutoCollisionRepiar DAM12-STMAN1-E Thispageisintentionallyleftblank. Textbook SteelStructureDamageAnalysis Contents Introduction..............................................................................................................................7 ObligationsToTheCustomerAndLiability.......................................................................... 7 Module1-VehicleStructures................................................................................................13 TypesOfVehicleConstruction........................................................................................... 13 TheCollision...................................................................................................................... 15 AnalyzingVehicleDamage................................................................................................ 18 AnalyzingVehicleDamage(con't)..................................................................................... 20 MeasuringForDamageAnalysis.........................................................................................25 ModuleWrap-Up............................................................................................................... 33 Module2-StructuralDamageAnalysis.................................................................................37 GeneralRepairConsiderations........................................................................................... 37 FrontImpact....................................................................................................................... 46 SideImpactDamageAnalysis............................................................................................ 52 RearImpactDamageAnalysis............................................................................................ 63 StationaryGlass.................................................................................................................. 66 Body-Over-FrameVehicles..................................................................................................70 ModuleWrap-Up............................................................................................................... 73 TableofContents 3 Thispageisintentionallyleftblank. Introduction Thispageisintentionallyleftblank. Textbook Introduction ObligationsToTheCustomerAndLiability • fit. • finish. Throughoutthedamageanalysisand repairprocesstherepairerandinsurer must: • communicatewitheachother. • maintainconstantcommunication withthecustomer. • beinagreementwitheachother andthecustomeronhowrepairs willbeperformed. TheCollisionRepairIndustryhas • informthecustomerofany anobligationtocorrectlyrepairthe changesintherepairplanfrom customer’svehicle.Collisionrepairsmust theoriginalrepairagreement,and beperformedusing: explainthechangesandwhythey havetobemade. • recommendedortested proceduresfromvehiclemakers, I-CAR,andotherresearchand testingorganizations. • qualityreplacementpartsand materials. • repairprocessesandpartsas writtenandagreeduponinthe repairorder. • Ifitemsontherepairagreement arenotconsistentwiththerepair order,itcanbeconsideredfraud. Performingpropercollisionrepairs Toreduceliability: requiresusingpartsandproceduresthat keepremainingwarrantiesintact. • makesurethatallrepairsare performedthoroughly,correctly Collisionrepairsmustrestore: andaslistedinthedamagereport. • followproperprocedures. • safety. • usequalityreplacementpartsand • structuralintegrity. materials. • durability. • performance. SteelStructureDamageAnalysis 7 Textbook Introduction • havedocumentationofrequired • thepolicymaynotcover repairswithdetailedrecord faultyrepairs,leavingliability keepingavailableforcustomers. responsibilitycompletelyonthe Techniciansareconsideredthe facility. expertsandareexpectedtobe • ashopownermayfindthatrepair knowledgeableonhowtoperform facilityliabilitycoveragemaynot aqualityrepair. coverthefullamountawardedin alawsuit.Theshopownerwould Keepingthoroughrecordsincludesmore havetopaythedifference. thanrecordingthedate,mileage,and pre-existingdamage.Recordkeeping alsoincludes:makingsureallnotesare legible. • verifyingtherepairsthatwere madeornotmade. • havingthecustomersigna waiverforrepairsthattheydo notwantperformed.Repairers mustdeterminetheirliabilityon notrepairingsafetysystemssuch Itisdifficulttoreducetheriskofliability asrestraintandanti-lockbrake exposure.Thepartthattherepairercan systems. controlisthechanceofbeingfoundat • keepingcomputerprintoutsor fault.Chancescanbeminimizedby: worksheetsonfileshowingwheel • usingrecommendedortestedproceduresfromthevehiclemakers,ICAR,or alignmentreadingsorvehicle otherresearchandtestingorganizations. dimensionsbeforeandafter • usingqualityreplacementpartsandmaterialsthatrestorefit,finish,durability, repairs. andperformatleastaswellastheoriginal. • keepingscantoolprintoutsand • keepingthoroughrecords. recordsofcomputercodesfor airbag,anti-lockbrake,emission, andpowertraincontrolmodule (PCM)systems.attachingtheOEM orothertestedprocedureprintout tothevehiclerepairorder. • keepingreceiptsforallsublet workperformed. Liabilityinsurancethatcoverstherepair facilitymaynotalwayscoveralldamages. Forexample: SteelStructureDamageAnalysis 8 Textbook Introduction Keepingthoroughrecordsincludesmore thanrecordingthedate,mileage,andpre- existingdamage.Recordkeepingalso includes: • makingsureallnotesarelegible. • verifyingtherepairsthatweremadeornotmade. • havingthecustomersignawaiverforrepairsthattheydonotwantperformed. Repairersmustdeterminetheirliabilityonnotrepairingsafetysystemssuchas restraintandanti-lockbrakesystems. • keepingcomputerprintoutsorworksheetsonfileshowingwheelalignment readingsorvehicledimensionsbeforeandafterrepairs. • keepingscantoolprintoutsandrecordsofcomputercodesforairbag,anti-lock brake,emission,andpowertraincontrolmodule(PCM)systems. • attachingtheOEMorothertestedprocedureprintouttothevehiclerepairorder. • keepingreceiptsforallsubletworkperformed. SteelStructureDamageAnalysis 9 Thispageisintentionallyleftblank. Module1-Vehicle Structures Thispageisintentionallyleftblank. Textbook Module1-VehicleStructures TypesOfVehicleConstruction • isbuiltwiththedrivetrain, steering,andsuspensionparts Learningobjectivesforthismodule mounteddirectlytothebody include: structure. • dependsoncorrectstructural • identifyingthedifferenttypesof alignmentforpropersteeringand vehicledesigns. suspensionalignment. • explaininghowunitizedstructures • iscommonlyusedformost aredesignedtocollapse. cars,anincreasingnumberof • identifyinghowdifferentimpact sport-utilityvehicles(SUVs),and anglestransfercollisionenergy sometrucks,suchastheHonda andcreatedifferenttypesof Ridgeline. damage. • readingvehiclemeasurementsto determinestructuraldamage. AudiR8 JaguarXF ThisisthespaceframeforanAudiR8. Spaceframevehicles: ThisJaguarXFunibodyshowstheinnerstructure withtheouterpanelsandtrimremoved. • aresimilartotheunibody structure. Aunibodystructure: • areunitizedstructureswith attachedouterbodypanels. • hasasinglestructurebuiltby • likeunibodystructures,have attachingmultiplepartsofsheet thedrivetrainandsteeringand metal.Attachmentmethods suspensionmountedtothebody includespotwelds,laserwelds, structure. rivets,adhesives,oracombination • likeunibodystructures,mayhave ofmethods. theouterpanelsattachedwith • hasexteriorwelded-onbody adhesives,fasteners,welds,ora panels,suchasroofsandquarter combinationoftheseattachment panels,includedintheoverall methods. structure. SteelStructureDamageAnalysis 13 Textbook Module1-VehicleStructures Theprimarydifferencebetweenspace • havetheengine,drivetrain,and framesandunibodystructuresisthat steeringandsuspensionparts spaceframesare: boltedtotheframe. • maybecalledfull-framevehicles. • lighterweight,eithermadefrom lightweightmetalorametaland Body-over-framedesignsinnon- compositestructurecombination. commercialapplicationsareusedfor • lessdependentonouterbody pickuptrucksandmanySUVs,vehicles panelsforstrength. primarilyusedforheavy-dutypurposes. • similartotheinnerstructure commononracecardesigns. FordF-150 FramesareeitherC-channel-typestyles(left)orbox- type(right). ModernpickuptruckandSUVframe designsvarydependingonthevehicle. Featuresofmodernframedesigns Abody-over-framevehiclehasaseparateunitized structurethatisboltedtotheframe. include: Body-over-framevehicles: • acombinationofcharacteristics frombothladder-typeand • haveaframeindependentofthe perimeter-typeframedesigns. unitizedstructure.Twomaintypes • bothopenC-channelandbox- offramesincludeperimeterand typerails. ladderdesigns.Ladderframesare • hydroformedrails.Box-typeand morecommononrecreational tubularhydroformedrailsare vehicles(RVs),busses,and flangeless,one-piecestructures commercialtrucks. formedfromametaltube.More • haveaseparateunitizedstructure informationonhydroformedparts boltedtotheframe.Ituses willbediscussedlaterinthe thesameenergymanagement course. characteristicsthatareusedfor • weldedorrivetedmounting unibodyvehicles. brackets. • crossmembersthatareweldedor rivetedtotheframe. SteelStructureDamageAnalysis 14 Textbook Module1-VehicleStructures • collapsezones. passengercompartment.Changingapart • torqueboxes. designorrepairingpartsthatshouldnot berepairedcanaffecttheoriginaldesign, ManypickuptrucksandSUVshave whichcanalterthecollisionenergy modernframeswithalowercenterof managementofthevehicle. gravityforbetterhandlingandamorecar- likeride. Itisimportanttonotethattherepairer and/orinsurermaybeliableforany TheCollision personalinjuryorpropertydamage