Optimization of a simplified automobile finite element model using time varying injury metrics

In 2011, frontal crashes resulted in 55% of passenger car injuries with 10,277 fatalities and 866,000 injuries in the United States. To better understand frontal crash injury mechanisms, human body finite element models (FEMs) can be used to reconstruct Crash Injury Research and Engineering Network (CIREN) cases. A limitation of this method is the paucity of vehicle FEMs; therefore, we developed a functionally equivalent simplified vehicle model. The New Car Assessment Program (NCAP) data for our selected vehicle was from a frontal collision with Hybrid III (H3) Anthropomorphic Test Device (ATD) occupant. From NCAP test reports, the vehicle geometry was created and the H3 ATD was positioned. The material and component properties optimized using a variation study process were: steering column shear bolt fracture force and stroke resistance, seatbelt pretensioner force, frontal and knee bolster airbag stiffness, and belt friction through the D-ring. These parameters were varied using three successive Latin Hypercube Designs of Experiments with 130-200 simulations each. The H3 injury response was compared to the reported NCAP frontal test results for the head, chest and pelvis accelerations, and seat belt and femur forces. The phase, magnitude, and comprehensive error factors, from a Sprague and Geers analysis were calculated for each injury metric and then combined to determine the simulations with the best match to the crash test. The Sprague and Geers analyses typically yield error factors ranging from 0 to 1 with lower scores being more optimized. The total body injury response error factor for the most optimized simulation from each round of the variation study decreased from 0.466 to 0.395 to 0.360. This procedure to optimize vehicle FEMs is a valuable tool to conduct future CIREN case reconstructions in a variety of vehicles.