Optimal crashworthiness design of vehicle S-frame using macro-element method and evolutionary algorithm

Abstract The paper presents the crashworthiness optimization of a thin-walled frame applied as energy-absorbing element in car structure. Crushing parameters S-frame are modeled using macro-element methodology. This method is implemented Visual Crash Studio software that enables very fast simulation structural behavior during impact. objective to determine optimal dimensions cross-section achieve maximal energy absorption. Moreover, selection best angle between segments investigated. In formulation problem, constraints related progressive collapse deformation zones, required by modeling, have been introduced. An Evolutionary Algorithm was search solution. A real-life example investigated numerical examples. attempt find solution solving sequence simpler problems with reduced number design variables approach compared result obtained for problem including all at same time. study illustrates potential early-design stages vehicle development process and prepares perspectives complex systems.