Optimal design of vehicle structure for improving small-overlap rating

This paper presents a study on the optimal design of vehicle structure for improving the small-overlap rating, based on a computer-based crash simulation model. Two reinforced component models such as longitudinal reinforcement and rocker panel reinforcement were developed for the small-overlap frontal impact simulation following the real test conditions. The crash simulation results were used to evaluate the overall vehicle structure through a comparison of intrusion measurements with the rating guidelines of the Insurance Institute for Highway Safety. The response surface method (RSM) was conducted to optimal vehicle structures in order to improve the small-overlap rating. The RSM function proposed the optimal values of the variables as the new design. The crash analysis results showed that the serious damage to the vehicle structure occurred when the minivan model collided with barrier model at 25% overlap. In this study, the grade of the overall structure was upgraded from “poor” to “acceptable” in the case of Flat 150 (the Flat barrier with a 150 mm radius and 25% overlap).