Optimization of a Modular Cockpit Cross Car Beam for Crashworthiness

In this paper, a numerical optimization of a cross car beam of a modular cockpit is presented. The optimization study was performed using LS-OPT code and LS-DYNA solver code. The optimization was based on component load level resulting from FMVSS214 dynamic side impact. The component load conditions were derived from a full vehicle simulation. The beam was subjected to axial load alone and to both axial and bending loads simultaneously. The beam was i) minimized for lower mass for a selected diameter and a given peak force to occur within 5mm axial deformation ii) optimal thickness of the beam for minimal effective plastic strain peak for a given resultant deformation