CAE Driven Improvement in Frontal Offset Crash Performance of a Compact Car 2014-01-0375

Offset crash compliance of a compact car is severe due to the compact layout and stringent fuel economy, weight and cost targets. Scope of the current work is to improve the structural crash performance of a compact car through CAE, in order to meet the offset frontal crash requirements as per ECE R94 Regulation.

The project has been classified in three main phases. First phase includes the evaluation of baseline vehicle in CAE. In order to ensure the accuracy of CAE prediction, a methodology for predicting Spotweld rupture was implemented. Using this methodology, it is possible to find out the location and time of spotweld rupture as well as propagation of spotweld rupture in CAE. CAE results of spotweld rupture prediction showed good agreement with the physical test. In second phase, design iterations were carried out in order to meet the performance targets of structural deformation. At critical locations of spotweld rupture, spotwelds were reinforced by addition of arc welds tugs and bolts. In third phase, all the structural countermeasures proposed in CAE were implemented in the prototype vehicle and physical crash test was conducted for final verification. Test and CAE results showed good correlation both in terms of the deformation and deceleration pulses. Significant improvement in offset crash performance of the vehicle was achieved with minimal weight and cost increase.