A Process of Decoupling and Developing Body Structure for Safety Performance

John M. Madakacherry, Dr. David Eby, Martin B. Isaac, Dr. Akbar Farahani, Dr. Charles A. Bruggeman, and Dr. Ron. C. Averill
Proceedings of the 5th European LS-DYNA Users Conference

A process for decoupling and developing an optimized automotive body structure for enhanced safety performance has been developed, implemented, and verified. The approach facilitates the development of a load path strategy and decoupling of a complex system into structural components or sub-systems, thus allowing for high-fidelty design optimization of a sub-system to meet desired performance targets. In the present study, the proposed approach was used to design a hydroformed motor compartment rail to meet the NCAP front crash and 40 mph 40% offset deformable barrier impact performance requirements, resulting in a 20% mass reduction and improved overall performance compared to a baseline design.  The decomposed subsets were developed through a combination of component-level DYNA3D analyses, linear dynamic, linear static analyses, and Genetic Algorithm techniques using HEEDS.
► Download (PDF, 1.65 MB)