Parameter and Optimization Studies for Crashworthiness Design using LS-DYNA and the Altair StudyWizard

In the automotive industry the crashworthiness of a design is of special interest. Non-linear finite element analysis, such as in LS-DYNA, is applied to predict the structural responses. Conclusions from these computations can lead to significant design modifications. Usually, intuition leads the iterative process of finding the best design. It is often hard to determine these design modification from the analysis results. In some cases many variations are tried before a satisfactory design is found [1]. Structural optimization and Design of Experiments Studies based on computational methods are useful tools to support the process of finding the right design. The complexity of the layout can be described mathematically as an optimization problem. Using the results of a computational optimization, the decision process can be improved. Optimization of structural elements can lead to significant cost reductions within the design process itself, or with regard to the final design. Industrial application of structural optimization depends on the availability of software products. For linear statics and dynamics such software is available and fairly well supported. Layout and shape optimization can be performed to design structural parts. In design considering crashworthiness no algorithms are available to perform sensitivity analysis and optimization as known in linear statics. An alternative approach is to use response surface methods in conjunction with such a code. Also, DOE approaches can be used.