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Finite element analysis of seat belt bunching phenomena

Abstract Some safety belt D-rings lead to a non-systematic instability; the webbing, which should scroll without hindrance through the D-ring, laterally shifts, bunches and produces the overturning of the ring. To expertise this so-called seat belt bunching phenomenon, finite element numerical simulations are undertaken at a mesoscopic scale. A new shell element is developed to simulate seat belt fabric behaviour. To support the finite element mesoscopic scale model, several tests on components are conducted and new test methods are focused on the seat belt behaviour. To correlate the model, an innovative fixture is used to reproduce the dynamic motion of the seat belt through the D-ring. To expertise the phenomenon, frontal sled tests are performed and a correlated model has been developed that allows to assess the instability phenomenon.