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PAM-CRASH Rollover and Roof Crush Simulation

30 Chapters
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01
Course overview
scope, regulatory drivers, and the role of PAM-CRASH in rollover and roof crush simulation.
regulatoryPAM-CRASH
02
Vehicle body-in-white modeling for rollover
geometry preparation, midsurface extraction, and mesh quality targets in PAM-CRASH.
body-in-whitemodeling
03
Material characterization for roof crush
elastic-plastic models, strain-rate effects, and failure criteria for steel and aluminum.
Materialcharacterization
04
Spot weld and structural joint modeling
connector types, failure modeling, and validation against physical tests.
structuralmodeling
05
Boundary conditions and loading fixtures
FMVSS 216a and ECE R29 setup, rigid plates, and contact definitions.
Boundaryconditions
06
Contact modeling in PAM-CRASH
penalty methods, friction, thickness offsets, and stabilization for large deformations.
modelingPAM-CRASH
07
Explicit time integration fundamentals
time step control, mass scaling, and energy balance checks for roof crush models.
Explicitintegration
08
Quasi-static roof crush simulation
load application, implicit vs. explicit approaches, and convergence strategies.
Quasi-staticsimulation
09
Dynamic rollover simulation
initial conditions, angular velocity, and ground interaction modeling.
rolloversimulation
10
Dolly rollover test setup
modeling the dolly, vehicle release, and ground contact in PAM-CRASH.
rollovermodeling
11
Occupant compartment integrity
defining survival space, measuring intrusion, and evaluating roof strength metrics.
Occupantcompartment
12
Roof crush force-displacement response
extracting peak force, energy absorption, and comparing to regulatory limits.
force-displacementresponse
13
Pillar and roof rail behavior
buckling modes, hinge formation, and progressive collapse mechanisms.
behaviorbuckling
14
Windshield and glazing modeling
laminated glass, fracture, and its contribution to roof stiffness.
Windshieldmodeling
15
Interior trim and occupant contact
modeling head impact, padding, and injury criteria relevant to rollover.
Interioroccupant
16
Seat belt and occupant restraint interaction
pretensioners, load limiters, and their effect on roof crush outcomes.
occupantrestraint
17
Sensitivity and robustness studies
parametric variations in thickness, material properties, and weld failure.
Sensitivityrobustness
18
Correlation with physical tests
data acquisition, filtering, and objective rating methods for roof crush.
Correlationphysical
19
Optimization of roof structure
gauge optimization, topology, and multi-objective trade-offs using PAM-CRASH.
Optimizationstructure
20
Composite and lightweight materials in roof structures
modeling challenges and failure prediction.
Compositelightweight
21
Rollover sensing and deployment logic
coupling PAM-CRASH with control system models.
Rolloverdeployment
22
Occupant kinematics in rollover
multi-body and finite element coupling for injury assessment.
Occupantkinematics
23
Post-processing and visualization
contour plots, section forces, and animation for engineering review.
Post-processingvisualization
24
Model validation and verification
mesh convergence, energy conservation, and comparison with test data.
validationverification
25
Regulatory compliance workflow
documentation, reporting, and traceability for FMVSS 216a and ECE R29.
Regulatorycompliance
26
Case study
full vehicle roof crush simulation from CAD to final report.
simulationCAD
27
Case study
dynamic rollover of an SUV with occupant compartment evaluation.
rolloverSUV
28
Advanced topics
ALE, SPH, and coupled methods for extreme deformation in rollover.
AdvancedALE
29
Automation and scripting in PAM-CRASH
Python macros, batch runs, and design of experiments.
Automationscripting
30
Future trends
electric vehicle roof structures, autonomous vehicle interiors, and simulation-driven certification.
electricstructures