Nonlinear finite element simulation is the state of the art tool to assess the crashworthiness performance of current automobile design. Despite all the advancements in today’s computational capabilities, simulations are still extremely computationally expensive. Moreover design optimization for crashworthiness is a highly nonlinear mathematical problem in which both analysis and optimization components are nonlinear and involve highly iterative process. This makes design optimization process prohibitively possible due to the associated unrealistic computational cost. This paper presents a practical approach that enables the designer to conduct design optimization for crashworthiness at an affordable computational cost.

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