How do you simulate crash scenarios and evaluate crashworthiness?

1 Finite Element Analysis

One of the most common methods to simulate crash scenarios is finite element analysis (FEA), which is a numerical technique that divides the vehicle and its components into small elements and applies the laws of physics and material properties to each element. FEA can model the dynamic behavior, deformation, stress, strain, and failure of the vehicle and its parts under different crash conditions, such as frontal, side, rear, rollover, or offset impacts. FEA can also account for the interaction between the vehicle and the environment, such as the road, barriers, or other vehicles. FEA requires sophisticated software, such as LS-DYNA, ANSYS, or ABAQUS, and high-performance computing to run the simulations and generate results.

2 Crash Test Dummies

Another method to simulate crash scenarios is to use crash test dummies, which are anthropomorphic devices that mimic the size, shape, weight, and biomechanics of human occupants. Crash test dummies are equipped with sensors and data recorders that measure the forces, accelerations, displacements, and pressures that they experience during a crash. Crash test dummies can provide valuable information about the injury risk and severity for different body regions, such as the head, neck, chest, abdomen, pelvis, and limbs. Crash test dummies can also represent different types of occupants, such as adults, children, infants, or pregnant women. Crash test dummies are used in physical crash tests, which involve crashing actual vehicles or vehicle parts into fixed or moving objects in controlled environments, such as laboratories or test tracks.

3 Multi-Body Dynamics

A third method to simulate crash scenarios is multi-body dynamics (MBD), which is a mathematical technique that treats the vehicle and its components as rigid or flexible bodies that are connected by joints, springs, dampers, or other elements. MBD can model the motion, interaction, and energy transfer of the vehicle and its parts under different crash conditions, such as braking, steering, or skidding. MBD can also incorporate the effects of the tires, suspension, steering, and brakes on the vehicle dynamics. MBD requires specialized software, such as ADAMS, SIMPACK, or MSC Software, and moderate computing power to run the simulations and generate results.

4 Crashworthiness Criteria

When evaluating crashworthiness, automotive engineers must consider several criteria that reflect the performance and safety of the vehicle and its occupants in a crash. These include structural integrity, occupant protection, injury criteria, and compatibility. To assess these criteria, engineers must analyze the data and results from the simulation methods and compare them with the standards and regulations that apply to the vehicle type, market, and scenario. This includes the Federal Motor Vehicle Safety Standards (FMVSS) in the US, the European New Car Assessment Programme (Euro NCAP) in Europe, or the Insurance Institute for Highway Safety (IIHS) in the US. Assessing these criteria is essential for ensuring that vehicles are safe and meet all necessary safety standards.

5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?