Improving Offset Crash Performance and Injury Mitigation via Multi-Body Simulation and Structural CAE

Recent advancement in numerical solutions and advanced computational power has given a new dimension to the design and development of new products.

The current paper focuses on the details of work done in order to improve the vehicle performance in Offset deformable Barrier (ODB) crash as per ECER-94. A Hybrid approach involving the Structural Crash CAE as well as Multi-body Simulation in MADYMO has been adopted. In first phase of the development, CAE results of Structural deformation as well as Occupant injury of the baseline model were correlated with physical test data. The second phase includes the improvement in intrusion and crash energy absorption by structural countermeasures in the vehicle body. In third phase parametric study has been carried out via Madymo simulation in order to decide on the factors which can be controlled in order to mitigate the Occupant injury. Recommendations of Madymo simulation have been confirmed by conducting Physical sled tests. Finally a cost and weight effective countermeasure package which involves the modification in Body structure and Restraint system has been developed in order to comply with the ECE R-94 offset crash regulation.