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Evaluation of pedestrian leg protection performance using the Flex-PLI-GTR (Flexible Pedestrian Legform Impactor Global Technical Regulation) impactor is initiated in JNCAP in 2011. Therefore, a finite element (FE) model of Flex-PLI-GTR is needed for use in digital car development in order to satisfy pedestrian leg protection performance requirements. This paper describes the FE model of Flex-PLI-GTR that has been developed to meet this need. There are three important features of this FE model for obtaining sufficient simulation accuracy. First, the shapes of all Flex-PLI-GTR structures were modeled in detail. Shape information of the inner structures was obtained by computerized tomography scanning and shape information of the inner structures of the outer skin was obtained by laser measurement. Furthermore, the shape of the wrapped skin was incorporated into the FE model based on a wrapping simulation.

Public concern about the crashworthiness of vehicles has been continuously rising in recent years. Crashworthiness is evaluated under various crash configurations, including frontal collisions, in regulatory testing and in New Car Assessment Programs. Accordingly, vehicle manufacturers must deploy sophisticated product development strategies and redouble their engineering efforts in order to develop vehicles that satisfy the specified requirements for crashworthiness. Computer simulation is one effective approach to resolving this issue in that it provides a valuable tool for conducting multiple parameter studies and iterations in a short period of time. However, it is no easy task for CAE engineers to analyze the large volumes of calculation results obtained in frontal crash simulations and to understand the phenomena involved.