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<p>Side impacts have been a grave concern to automobile engineers, as they injure and kill numerous people each year. The high computational cost of numerical models with full-size vehicles, however, challenges engineers to find the optimal crashworthiness structural design solution. This study aims to reduce the computational cost of side impact simulations by proposing a novel sub-modeling simplification approach with the double-mass points (DMP) method. This method splits the vehicle into front and back areas, about the B-pillar, and in ‘struck’ and ‘unstruck’ sides. The full vehicle structure (but its two wheels) from the unstruck side is removed about the vehicle centerline. This removed unstruck side’s front and rear areas are replaced by their equivalent mass (DMP), each at their center of gravity. These masses are then connected to the wheels of the unstruck structure as well as the centerline of the remaining structure of the struck side. This method reduces the model size for faster computation. Validated Rogue, Yaris, and Caravan full-size numerical finite element models, provided in the literature, generate side impact cases, including a moving deformation barrier (MDB) and pole-side impact scenarios. The vehicle deformation, B-pillar intrusion and acceleration, and door inner panel intrusion of the full-size and simplified models are compared to evaluate the effectiveness of the simplified modeling methods. Results demonstrate that the crushing response of DMP simplified models is captured well compared to full-size computer models. Besides, the DMP simplified models provide a 37.40, 34.24, and 16.82% computation runtime reduction in MDB impact than the baseline full-size models (27.81&#xa0;h in the Rogue model, 11.48&#xa0;h in the Yaris model, 3.86&#xa0;h in the Caravan model), respectively. Furthermore, the DMP simplified model presents a 42.89, 44.40, and 37.64% lower computation runtime compared to three full-size models subjected to pole impact (24.06&#xa0;h in Rogue, 9.38&#xa0;h in Yaris, and 1.90&#xa0;h in Caravan), respectively. The DMP simplified model development approach significantly reduces vehicle model simulation time, accelerating the development of side impact structures. During the vehicle concept stage, where understanding structural packaging, such as reinforcement locations and size, is crucial. This new method should be invaluable in defining and validating vehicle architecture at the earliest design phase.</p>

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A novel simplification method for vehicle crashworthiness simulation subject to side impact

  • 期刊论文

  • 发表日期：

    2025年9月2日

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  • Rui Liang,
  • Hongwei Wei,
  • Yonggang Sun,
  • Wangjie Tuo,
  • Christophe Bastien

摘要

Side impacts have been a grave concern to automobile engineers, as they injure and kill numerous people each year. The high computational cost of numerical models with full-size vehicles, however, challenges engineers to find the optimal crashworthiness structural design solution. This study aims to reduce the computational cost of side impact simulations by proposing a novel sub-modeling simplification approach with the double-mass points (DMP) method. This method splits the vehicle into front and back areas, about the B-pillar, and in ‘struck’ and ‘unstruck’ sides. The full vehicle structure (but its two wheels) from the unstruck side is removed about the vehicle centerline. This removed unstruck side’s front and rear areas are replaced by their equivalent mass (DMP), each at their center of gravity. These masses are then connected to the wheels of the unstruck structure as well as the centerline of the remaining structure of the struck side. This method reduces the model size for faster computation. Validated Rogue, Yaris, and Caravan full-size numerical finite element models, provided in the literature, generate side impact cases, including a moving deformation barrier (MDB) and pole-side impact scenarios. The vehicle deformation, B-pillar intrusion and acceleration, and door inner panel intrusion of the full-size and simplified models are compared to evaluate the effectiveness of the simplified modeling methods. Results demonstrate that the crushing response of DMP simplified models is captured well compared to full-size computer models. Besides, the DMP simplified models provide a 37.40, 34.24, and 16.82% computation runtime reduction in MDB impact than the baseline full-size models (27.81 h in the Rogue model, 11.48 h in the Yaris model, 3.86 h in the Caravan model), respectively. Furthermore, the DMP simplified model presents a 42.89, 44.40, and 37.64% lower computation runtime compared to three full-size models subjected to pole impact (24.06 h in Rogue, 9.38 h in Yaris, and 1.90 h in Caravan), respectively. The DMP simplified model development approach significantly reduces vehicle model simulation time, accelerating the development of side impact structures. During the vehicle concept stage, where understanding structural packaging, such as reinforcement locations and size, is crucial. This new method should be invaluable in defining and validating vehicle architecture at the earliest design phase.