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PAM-CRASH Vehicle Side Impact Simulation

30 Chapters
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01
Side impact crashworthiness fundamentals
regulatory and consumer test protocols, injury criteria, and the role of explicit finite element simulation in vehicle side impact design.
crashworthinessregulatory
02
PAM-CRASH solver architecture for side impact
explicit time integration, contact algorithms, material models, and the PAM-CRASH input deck structure for crashworthiness simulations.
PAM-CRASHarchitecture
03
Vehicle side structure modeling
B-pillar, rocker, door beam, roof rail, and floor cross-member representation using shell, solid, and beam elements in PAM-CRASH.
structuremodeling
04
Material modeling for side impact
strain-rate-dependent steels, aluminum alloys, tailored blanks, and the selection of Johnson-Cook, Cowper-Symonds, and GISSMO damage models.
Materialmodeling
05
Geometry preparation and meshing strategies
CAD cleanup, midsurface extraction, mesh quality criteria, and element size selection for side impact crash models.
Geometrypreparation
06
Connection and joint modeling
spot welds, seam welds, adhesive bonding, rivets, and bolted joints using PAM-CRASH connector elements and failure criteria.
Connectionmodeling
07
Barrier and impactor modeling
moving deformable barrier (MDB), side impact pole, and rigid wall definitions with initial velocity and contact interface setup.
impactormodeling
08
Occupant and restraint system representation
dummy positioning, seat belt routing, side airbag deployment, and occupant kinematics coupling in PAM-CRASH.
Occupantrestraint
09
Contact definition and management
self-contact, surface-to-surface contact, edge-to-edge contact, friction coefficients, and contact thickness handling for side impact.
definitionmanagement
10
Boundary conditions and loading
initial velocity assignment, gravity, prescribed motion, and the correct application of symmetry and constraint conditions.
Boundaryconditions
11
Time step control and mass scaling
critical time step calculation, selective mass scaling, and its influence on side impact simulation accuracy and stability.
criticalcalculation
12
Hourglass control and energy balance
hourglass modes, viscous and stiffness-based control, and monitoring of energy ratios for reliable side impact results.
Hourglassstiffness-based
13
Running PAM-CRASH simulations
solver invocation, parallel processing options, restart capability, and checkpointing for long-duration side impact analyses.
PAM-CRASHsimulations
14
Post-processing with PAM-VIEW
deformation plots, stress and strain contours, section forces, intrusion measurements, and animation of side impact events.
Post-processingPAM-VIEW
15
Intrusion and deformation metrics
B-pillar intrusion, door panel displacement, rocker deformation, and occupant survival space quantification from simulation results.
Intrusiondeformation
16
Injury criteria extraction
Euro NCAP side impact scoring, WorldSID and ES-2 dummy responses, rib deflection, abdominal force, and head injury criteria from PAM-CRASH output.
criteriaextraction
17
Correlation with physical tests
test data acquisition, signal filtering, objective rating methods, and iterative model updating for side impact validation.
Correlationphysical
18
Mesh convergence and sensitivity studies
element size effects, mesh transition, and parametric sensitivity of side impact responses to modeling choices.
convergencesensitivity
19
Design of experiments for side impact
DOE setup in PAM-CRASH, parameter selection (thickness, material grade, geometry), and response surface generation.
experimentsDOE
20
Optimization of side structure
topology, shape, and size optimization using PAM-CRASH results coupled with optimization tools for weight and intrusion targets.
Optimizationstructure
21
Advanced material modeling
composite materials, high-strength steel grades, and failure modeling for side impact energy absorption.
Advancedmaterial
22
Side airbag and curtain airbag simulation
deployment modeling, fluid-structure interaction, and occupant protection performance evaluation.
simulationdeployment
23
Battery electric vehicle side impact
battery pack enclosure modeling, cell crush simulation, and electrical short-circuit risk assessment in PAM-CRASH.
electricenclosure
24
Pedestrian and cyclist side impact
head and leg impactor modeling, windshield and A-pillar interaction, and pedestrian protection compliance simulation.
Pedestrianimpactor
25
Multi-body and coupling approaches
PAM-CRASH coupling with MADYMO or other occupant simulation tools for integrated side impact safety assessment.
Multi-bodycoupling
26
Robustness and variability
stochastic simulation, manufacturing tolerances, material scatter, and probabilistic side impact performance evaluation.
Robustnessvariability
27
High-performance computing for side impact
cluster setup, domain decomposition, GPU acceleration, and cloud-based PAM-CRASH simulation workflows.
High-performancecomputing
28
Automation and scripting
PAM-CRASH command language, Python scripting for model generation, batch runs, and automated post-processing of side impact results.
Automationscripting
29
Case study
full vehicle side impact simulation — model assembly, boundary conditions, run execution, and result interpretation for a passenger car.
simulationassembly
30
Case study
side pole impact and MDB impact — comparative analysis, design improvement iterations, and final validation against regulatory requirements.
MDBcomparative