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Automotive Physical Crash Testing and CAE Correlation

30 Chapters
View Course Samples Online
01
Course overview
scope, concepts, and technical context of automotive physical crash testing and CAE correlation.
technicalautomotive
02
Crash test facility setup
sled test systems, barrier types, and data acquisition for full-scale vehicle impacts.
facilityacquisition
03
Instrumentation for physical crash testing
accelerometers, load cells, strain gauges, and high-speed cameras.
Instrumentationphysical
04
CAE model build for crash simulation
mesh generation, material models, and boundary conditions.
CAEsimulation
05
Frontal impact test protocols
FMVSS 208, Euro NCAP, and C-NCAP procedures and acceptance criteria.
protocolsFMVSS
06
Side impact test protocols
FMVSS 214, IIHS side impact, and pole test configurations.
protocolsFMVSS
07
Rear impact and roof crush testing
FMVSS 301, FMVSS 216, and whiplash assessment.
FMVSSwhiplash
08
Pedestrian protection testing
EEVC WG17, Euro NCAP pedestrian test, and legform impactors.
Pedestrianprotection
09
Occupant restraint system validation
airbag deployment, seatbelt load limiting, and dummy response.
Occupantrestraint
10
Crash test dummy instrumentation and calibration
Hybrid III, THOR, and WorldSID.
instrumentationcalibration
11
Data processing from physical tests
filtering, integration, and injury criteria calculation (HIC, BrIC, etc.).
processingphysical
12
CAE correlation metrics
objective rating methods, CORA, and statistical validation.
CAEcorrelation
13
Mesh sensitivity and time step optimization for crashworthiness simulation.
Mesh sensitivity and time step optimization for crashworthiness simulation.
sensitivityoptimization
14
Material characterization for crash CAE
strain rate effects, failure criteria, and spot weld modeling.
Materialcharacterization
15
Validation of frontal impact CAE models against physical test data.
Validation of frontal impact CAE models against physical test data.
ValidationCAE
16
Validation of side impact CAE models
door intrusion, B-pillar, and occupant kinematics.
ValidationCAE
17
Rear impact CAE correlation
seat structure, head restraint, and whiplash prediction.
CAEcorrelation
18
Pedestrian protection CAE correlation
headform, legform, and upper legform impact simulations.
Pedestrianprotection
19
Occupant restraint system CAE correlation
airbag FSI, seatbelt routing, and dummy positioning.
Occupantrestraint
20
Sensitivity analysis and design of experiments for crash CAE model calibration.
Sensitivity analysis and design of experiments for crash CAE model calibration.
Sensitivityanalysis
21
Uncertainty quantification in physical testing and CAE correlation.
Uncertainty quantification in physical testing and CAE correlation.
Uncertaintyquantification
22
Correlation of high-speed crash test data with CAE for electric vehicle battery packs.
Correlation of high-speed crash test data with CAE for electric vehicle battery packs.
Correlationhigh-speed
23
Correlation for lightweight material structures
aluminum, magnesium, and composites.
Correlationlightweight
24
Correlation for joining technologies
spot welds, adhesives, and rivets under crash loads.
Correlationtechnologies
25
Full vehicle CAE model updating using physical test results
mass, stiffness, and damping tuning.
CAEupdating
26
Regulatory and consumer rating correlation
passing FMVSS and achieving 5-star NCAP ratings.
Regulatoryconsumer
27
Case study
frontal offset crash correlation for a midsize sedan.
correlation
28
Case study
side pole impact correlation for an SUV with battery electric powertrain.
correlationSUV
29
Case study
pedestrian head impact correlation for a hood and fender design.
pedestriancorrelation
30
Future trends
virtual testing, AI-assisted correlation, and real-time hybrid simulation.
AI-assistedcorrelation