In order to meet the Federal Motor Vehicle Safety Standards (FMVSS) requirement, the frontal structure of the vehicle needs to be design to maximize energy absorption in the presence powertrain design layout constraint. This needs the basis for structural optimization using a pragmatic approach. With regards to passive safety of a vehicle, there is a constant increase of the requirements to the BIW (Body in White) stiffness in ever greater extent, without a significant increase in vehicle weight. The primary objective of this study is to demonstrate mass optimization in a virtual tryout chain and generate optimized analytical model that can be leveraged in future assessment of a car. For this, a parameter investigation concerning variation of input data is done using I-sight. Simplified model of the bumper subsystem is developed for the offset crash test to serve as a base for the creation of designs by changing design variables. The optimization is carried out using I-sight to explore design space for this subsystem. Finally the effectiveness of optimized bumper subsystem is examined using full vehicle impact test. The focus of the work is further promoting the trend for light weight construction by weld optimization. Overall, this virtual tryout leads in sustainability by lighter transport on road, thus saving fuel and reducing emission.

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