This paper presents a novel method for shape optimisation for crashworthiness design of passenger cars based on the software SFE CONCEPT. In contrast to classical morphing approaches, SFE CONCEPT allows for larger geometrical modifications via an implicit parameterisation technique. This is advantageous in particular in the early design phases where different design alternatives are investigated and the optimal and robust geometry needs to be identified. As first example, the front rail of a standard passenger car is optimised here which is - as one of the main parts of the body in white - an appropriate example for exploration of optimisation methods. The performance of a classical optimisation is analysed and complemented by a robustness analysis where for the first time in crashworthiness design uncertainties in shape parameters are considered. Especially in early design stages, the optima obtained via an automated algorithm have to be assessed with respect to inevitable fluctuations in design and noise variables. Therefore, in the final part of this paper, the results of a robust design optimisation approach are evaluated.     «

This paper presents a novel method for shape optimisation for crashworthiness design of passenger cars based on the software SFE CONCEPT. In contrast to classical morphing approaches, SFE CONCEPT allows for larger geometrical modifications via an implicit parameterisation technique. This is advantageous in particular in the early design phases where different design alternatives are investigated and the optimal and robust geometry needs to be identified. As first example, the front rail of a sta...     »