Crashworthiness Design of Frontal Rail Using Strain-Energy-Density and Topology Optimization Approach

The frontal rail structure, which profoundly affect automotive frontal crashworthiness, must have an adjust deformation behavior and excellent energy absorbing ability. This work aims to explore the proper material distribution to improve its bending mode to axial crush mode. Since the nonlinear finite element analysis to obtain sensitivities is high computational complexity, the strain-energy-density (SED) method is put forward to calculate the stiffness distribution under equivalent static loads condition. Topology optimization approach is also investigated by considering different crush characteristics. Thus, the locations of the reinforcement plates and triggers can be distributed reasonably. The results demonstrate the capability and potential of the approach and process proposed in the crashworthiness design of auto body structure.