Accurate FEA Predictions for Roof Crush Performance of Automotive Structures

The ability to accurately predict roof crush strength as well as the timing of structure intrusion is of great importance in the enhancement of the automotive roof design. Roof crush performance is a complex nonlinear phenomenon involving large-scale deformations and strains with many structural parameters influencing the performance. FMVSS216 testing is being used as an industry standard to determine the sufficiency of body structure strength against a stipulated roof crush load. In this paper, sensitivity of roof crush strength and stiffness predictions in a finite element simulation of FMVSS216 testing condition is studied systematically. Various physical parameters and their mathematical representation in finite element simulations are examined for their contribution to body structure strength as well as stiffness against roof crush loads. In this paper, optimal combination of physical and computational parameters is developed for accurate CAE predictions when compared to the corresponding physical test depictions for roof crush performance of automotive structures.