An FEA-Based Concept Evaluation Tool For Early Vehicle Body-in-White Development

Abstract

Traditional crash simulation approaches are typically time-consuming and require highly detailed vehicle models, which are often unavailable during the early stages of product development. To address this limitation, Volvo Cars Corporation (VCC) employs an internal concept evaluation tool that allows designers to perform preliminary structural analyzes and ensure designs meet subsystem-level requirements at an early phase. This thesis focuses on the further development of this concept evaluation tool by addressing its existing drawbacks, thereby enhancing its versatility, efficiency, and accuracy to better support early-stage design. By pairing Python-driven automation with LS-DYNA, the proposed framework transforms repetitive routine into a streamlined, standardized workflow. Scripts regenerate meshes, reapply boundary conditions, and relaunch the simulation the moment a design variable is set. The developed system framework uses the threepoint bending scenario, identified as one of the most critical load cases in vehicle structural assessments, as a representative example to build an automated preprocessing module. In addition, an automated error handling layer was integrated into the framework. It effectively intercepts issues such as problematic meshes, incorrect coordinate systems, or solver warnings early in the process, thereby preventing contamination of results. Due to automation, engineers can conveniently preset cross-sectional parameters such as dimensions, materials, boundary conditions, and other essential inputs. Even under rapid development cycles, all required parameters can be applied correctly and consistently. Finally, all benefits mentioned above are integrated into a unified graphical interface. It is intuitive enough for design engineers to guide themselves through all steps of the simulation setup, paying attention to the most crucial aspects while minimizing exposure to non-essential components. The framework transforms previously manual processes into automated workflow and background computations, enabling faster and more accurate numerical results.