Reverse Engineering Method for Developing Passenger Vehicle Finite Element Models 1999-01-0083

A methodology to develop full-vehicle representation in the form of a finite element model for crashworthiness studies has been evolved. Detailed finite element models of two passenger vehicles - 1995 Chevy Lumina and 1994 Dodge Intrepid have been created. The models are intended for studying the vehicle’s behavior in full frontal, frontal offset and side impact collisions. These models are suitable for evaluating vehicle performance and occupant safety in a wide variety of impact situations, and are also suitable for part and material substitution studies to support PNGV (Partnership for New Generation of Vehicles) research.

The geometry for these models was created by careful scanning and digitizing of the entire vehicle. High degree of detail is captured in the BIW, the front-end components and other areas involved in frontal, frontal offset and side impact on the driver’s side. Mass, center of gravity and moment of inertia were matched at the component level and at the full vehicle level. The models represent the vehicle in mass, moments of inertia and crashworthiness performance. Vehicle responses in the different crash modes - 56 km/h (35 mph) frontal (NCAP), 64 km/h (40 mph) offset (IIHS) and 53.6 km/h (33.5 mph) side impact (FMVSS 214), were validated by comparing with actual vehicle test responses. Good agreement between the test results and finite element simulation was found.