Abstract
Crash load cases usually take longer simulation times due to the highly nonlinear nature of the analysis and complexity of the simulation models. In this paper, a sub structuring approach is proposed for faster simulation turnaround time, by partitioning complex vehicle system into simple sub structure model. The boundary conditions of the substructure models are identified based on the deformation of the critical load path members, vehicle kinematics, resistance force and energy absorption etc. Low speed, pedestrian & Door intrusion load cases are demonstrated in this paper using substructure approach. In case of Low speed impact, the vehicle front end deformation energy is considered as a critical parameter to define the boundary conditions of the sub structure model. Similar approach is followed to define other load cases and the developed sub structure models show good correlation with corresponding full vehicle CAE models. This approach enables the engineers to make quick decisions and faster design convergence during virtual validation phase. From the results, it has been concluded that more than 60% of simulation time is reduced which in turn leads to huge simulation cost & time saving during product design cycle.