Computational Analysis of Automotive Crashworthiness

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Insinööritieteiden korkeakoulu | Bachelor's thesis
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Date

2025-09-05

Department

Major/Subject

Computational Engineering

Mcode

ENG3082

Degree programme

Aalto Bachelor’s Programme in Science and Technology

Language

en

Pages

30+7

Series

Abstract

This bachelor’s thesis, which is completed as a literature review, covers topics regarding material selection, reinforcement types, structural design choices, and computational modelling in terms of automotive crashworthiness. Analyses are provided on how various materials possess differentiating failure mechanisms to absorb energy, how structural design choices contribute to crash performance, and how computational modelling techniques support development. Regarding material selection, most of the analysis is focused on steels and composite materi-als, where steels exhibit ductile deformation with strain hardening, whereas com-posites offer weight reduction but generally absorb less total energy. Structural concepts such as folding membranes, crash boxes, and stiffened or reinforced panels are shown to enhance the efficiency of energy absorption. In terms of com-putational modelling, the finite element method is concluded as the most accurate and trustworthy model, but it requires substantial computational costs and time. The thesis concludes that no single modelling approach or material selection en-sures optimal crashworthiness. Rather, combining ductile metals with lightweight composites, utilising reinforced structural designs, and integrating FEM with simplified analytical models and physical tests results in the most effective work-flow towards lighter, safer, and more efficient vehicle structures.

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Supervisor

St-Pierre, Luc

Thesis advisor

Romanoff, Jani

Keywords

analytical models, composite materials, crashworthiness, finite element method, folding, geometric nonlinearity

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https://urn.fi/URN:NBN:fi:aalto-202510077447

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