Simplifying a full vehicle model for FE-analysis

Finite element (FE) simulation allows an evaluation of crash safety early during the development of new vehicles. While the CAD model has to be as accurate as possible for evaluating, e.g. the packaging, the simulation model needs to be simplified geometrically, in order to generate less CPU-intensive calculations. It is important to provide results within a reasonable time to obtain the advantage of the simulation as fast responding tool during the design process. Therefore the overall goal is to represent most components with surfaces and shell elements, while maximising the edge length of the element, resulting in the need for simplified CAD data. Simplifications of the CAD data are not possible in many cases or very time consuming as the software for generating the FE mesh commonly receives the final CAD data as simple 3D geometry without the in depth design information from the CAD. Consequently simplifications are often realised by reproducing complete CAD components. This presentation shows the processing of input CAD for FE crash simulations by using Altair Hyperworks combined with solidThinking Inspire. The combination of both software tools enables fast and easy modifications of detailed CAD models. The work within this presentation was performed within the RESOLVE - Range of Electric SOlutions for L-category Vehicles - project, a three year research project co-funded by the European Commission within the H2020 program (Call: H2020-GV-2014, Grant Agreement No 653511).