A finite element model of component solution space for early stage design uncertainties

This work proposes a new method for testing a component for crashworthiness in a new car early development phase. The method accounts for the relations between components to assess how the development uncertainties (i.e. epistemic uncertainties) affect the performance of the one currently tested. Common tests, like a drop tower set-up, fail at capturing how other components can affect the performance itself. Hence, we propose a new Finite Elements simplified model where all components involved in a frontal crash are represented. To capture these relations, we couple 1D elements with the full mesh of the component to study. Solution Space, then, characterizes all uncertainties. These are inputs to the 1D element behavior. Running 10,000 samples confirms the method to work: the simulations are stable, and we capture how one component is affected by the others. When still no design is available for other parts, developers now have a new tool to test how robust their design is in relation to the interactions with these unknown other components.