Reduce Cost of Product Design using Unit FE Simulation 2016-01-1371

The unit analysis methodology can be used for designing component or product in a product development process. This method may be used for designing the crush can, bumper beam, crush can long member, B-frame or A-pillar in frontal impact analysis. Unit assembly model technique can be effectively used in many CAE load cases to evaluate CAE simulations such as pedestrian impact analysis (ECE R78 / ENCAP), interior trim related head impact simulations (FMVSS201U), under run protection simulation for commercial vehicles (Front Underrun Protection Device ECE R93, Rear Underrun Protection Device ECE R58, Side Underrun Protection Device ECE R73), airbag deployment optimization etc. These CAE analyses correlate better with actual test. This paper gives idea about how the cost of product design can be reduced by using unit analysis. To reduce time of vehicle development such as cost of prototype, testing cost, optimization cost unit analysis is more economical. In this paper, one illustrative CAE example shows that how cost and time required for designing product and development using unit assembly simulation is reduced drastically as compared to full vehicle simulation. Using unit analysis, complexity of work is reduced from high to low. CPU run time cost is reduced with high margin as compared to full vehicle simulation. In automotive product development, one can use unit analysis method.