Crash target integration during the design and optimization process of a high performance car chassis

Vincenzo Rotondella, Enrico Andreoli, Paolo Fabbro

Università degli Studi di Modena e Reggio Emilia


The set-up process of a high performance car chassis involves a compromise between many targets in different loading conditions that need to be satisfied in order to achieve global performance. The first phase of the design process is focused on static targets as torsional (Kt) and bending (Kb) stiffness. Available numerical optimization techniques, such as topology or shape optimization, are useful tools in this first phase to approach and refine the design process. During the following phases the car chassis is subjected to a review loop with the intention of reaching other objectives such as fatigue, NVH and also crash targets. The crashworthiness design aspect is considered to be a complex phase of the procedure because requires a long set-up, running and tuning time and leads easily to severe modification to the first design phase results, meaning also considerable weight additions that are not taken in account in the first structural optimization phase. The aim of this paper is to present a methodology that integrates the crash targets in the very first phase of the design process in order to be predictive of the chassis crashworthiness reducing both the overall design process time and the total weight of the car, so the overall efficiency of the project.