In this paper, new advances in simulation of car frontal crash structure are presented. Experimental results have been used to calibrate constitutive material models and simulation procedures to obtain more accurate representation of material behavior under crash loading. These advanced computational techniques are then applied to the crash simulations of components. The front longitudinal beam studied in this paper is analyzed for frontal crash. Qualitative results on specific energy absorption, as well as the absolute energy absorbed by the structure, are especially relevant. Three designs are then proposed as potential solutions for the front side rail design. Through simulation of their impact into a wall the designs are compared on the basis of crush force and specific energy absorption and a preferred design is chosen.

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