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A simplification and optimization approach for vehicle crashworthiness analysis: application on the NCAP MPDB crash test

Lualdi, Pietro and Schäffer, Michael and Sturm, Ralf (2022) A simplification and optimization approach for vehicle crashworthiness analysis: application on the NCAP MPDB crash test. In: Advances in Structural Dynamic Simulation. Advances in Structural Dynamic Simulation - Nafems, 2022-03-29 - 2022-03-30, Online. (Unpublished)

[img] PDF - Only accessible within DLR
[img] PDF - Only accessible within DLR


in the field of crashworthiness design, exploiting the full potential of weight reduction techniques while preserving the high safety standards of a vehicle still remains one of the major challenges. The computational cost of FEM simulations required to analyze the various crash load cases represents a real limitation to the optimization of vehicle structures. This aspect gets more relevant in load cases that include additional complex impactor models such as deformable barriers. To keep up with the ever-shorter stages of the Product Development Process (PDP), full vehicle crash models cannot be used directly for crashworthiness optimization. Similarly, conventional optimization approaches (e.g. based on Monte Carlo methods) cannot be applied successfully either. Therefore, there is a strong need for an automatic generation of simplified vehicle crash models. The main goal is the reduction of computational time while keeping the deviation of the simulation results as small as possible. This also enables structural optimization by means of suitable approaches that can operate with a minimal number of solver calls. In this work, an automated four-step approach to generate a simplified vehicle model and a simplification approach for deformable barriers are presented. Applying these approaches for the US NCAP front load case (100%, 56 km/h) with a validated Toyota Yaris model revealed that the number of components in the model could be reduced by 50%, and the computational time can be reduced by up to 90%. To show a suitable optimization approach with simplified FEM models, the Urban Modular Vehicle (UMV) designed by the German Aerospace Center (DLR) is investigated within the NCAP Mobile Progressive Deformable Barrier (MPDB) crash load case. A design optimization strategy based on mathematical surrogate models is successfully applied to optimize the absorption properties of the relevant structural components under specific safety constraints. As a final result, the Specific Energy Absorption (SEA) is more than doubled.

Item URL in elib:https://elib.dlr.de/187724/
Document Type:Conference or Workshop Item (Keynote)
Title:A simplification and optimization approach for vehicle crashworthiness analysis: application on the NCAP MPDB crash test
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Lualdi, PietroUNSPECIFIEDhttps://orcid.org/0000-0001-9722-6185UNSPECIFIED
Date:30 March 2022
Journal or Publication Title:Advances in Structural Dynamic Simulation
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Keywords:Simplification approach; Model Order Reduction; Surrogate Based Optimization; Crashworthiness Optimization.
Event Title:Advances in Structural Dynamic Simulation - Nafems
Event Location:Online
Event Type:international Conference
Event Start Date:29 March 2022
Event End Date:30 March 2022
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Road Transport
DLR - Research area:Transport
DLR - Program:V ST Straßenverkehr
DLR - Research theme (Project):V - FFAE - Fahrzeugkonzepte, Fahrzeugstruktur, Antriebsstrang und Energiemanagement
Location: Stuttgart
Institutes and Institutions:Institute of Vehicle Concepts > Vehicle Architectures and Lightweight Design Concepts
Deposited By: Lualdi, Pietro
Deposited On:04 Aug 2022 13:39
Last Modified:24 Apr 2024 20:49

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