Cross-Section Optimization for Axial and Bending Crushes Using Dual Phase Steels

To achieve optimal axial and bending crush performance using dual phase steels for components designed for crash energy absorption and/or intrusion resistance applications, the cross sections of the components need to be optimized. In this study, Altair HyperMorph™ and HyperStudy^® optimization software were used in defining the shape design variables and the optimization problem setup, and non-linear finite element code LS-DYNA^® software was used in crush simulations. Correlated crash simulation models were utilized and the square cross-section was selected as the baseline. The optimized cross-sections for bending and axial crush performance resulted in significant mass and cost savings, particularly with the application of dual phase steels.