Advanced Finite Element Analysis and Optimization of Automotive Crashworthiness in Vehicle Impact Scenarios

Abstract

This study explores advanced finite element analysis (FEA) techniques and optimization strategies to enhance vehicle crashworthiness under various impact scenarios. Utilizing high-fidelity FEA models of a mid-size sedan, we simulate frontal, side, and rear impacts across multiple collision speeds and angles. Model components include deformable chassis, seatbelts, airbags, and realistic material behaviors such as strain-rate dependency and failure criteria. We leverage automated meta-modeling and topology-based shape optimization to redesign critical structural elements. Simulation outputs—intrusion depths, deceleration profiles, and structural deformation modes—are analyzed to assess occupant protection enhancements. Optimizations target a 15–25% reduction in cabin intrusion and a 20% improvement in energy absorption capacity, while adhering to mass and manufacturability constraints. Experimental correlation using full-scale sled tests validates the FEA framework within ±7% for key metrics. Results demonstrate that optimized subframe and rocker panel geometries yield meaningful crashworthiness gains with only minor mass impact (~2%). This integrative FEA-optimization pipeline offers a scalable approach for vehicle front-loading in early-stage design, contributing to safer automotive architectures.