The automotive industry continuously strives to enhance safety for both drivers and passengers through technological advancements. Car side impacts have the potential to significant risks to passengers, So the automotive industry has proposed various technological solutions. As part of these efforts, the development of side impact beams, which are affixed to the inner frame of vehicle side doors to absorb and dissipate collision energy, has been a safety enhancement. Conventional side impact beams are manufactured using hot-rolled steel sheets and have a pipe-like configuration. However, these impact beams are fixed to the vehicle's chassis, which directly transfers the energy generated during a collision to the chassis frame. This paper aims to address this issue by proposing the development and optimization of vehicle door impact beams using a dual-beam structure and fastening method, utilizing shear bolts. Moreover, the focus is on optimizing the cross-sectional shape of the dual-beam impact structure. The evaluation criterion for optimization is based on the second moment of area of the cross-section. To validate these improvements, Static experiments were conducted, comparing the proposed dual-beam structure with the traditional impact beam. This research is expected to serve as a guideline for enhancing vehicle safety through design directions and validation methods.

This study aims to evaluate structural safety through FEM on the hollow shaft and the shaft filled with aluminum foam as the impact beam made of high tensile strength steel, Force reactions of impact beams are investigated when the forced displacement of 50mm is applied equally on two beams. When impact velocity of 80km/h is applied onto impact beams equally with the limit velocity of automobile on national road, how much impact energies can be absorbed by beams are also investigated. As study result, impact beams without aluminum foam and with aluminum foam show the maximum reaction forces of 15.53kN and 20.34kN respectively in case of the forced displacement of 50mm. As impact analysis result, impact beams without aluminum foam and with aluminum foam can absorb impact energies of 560J and 820J respectively. As impact beam with aluminum foam has reaction force and impact energy more than 23% and 30% than without aluminum foam, impact beam with aluminum foam has more safety than without aluminum foam.

The computer-based simulation tools are currently used overwhelmingly to simulate the performance of automotive designs. Then, the search for an optimal solution that satisfies a number of performance requirements usually involves numerous iterations amon