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Modelling of links in a numerical simulation to improve occupant safety during side impact

Abstract During side impact, door panels must be designed according to the original equipment manufacturer's passive safety requirements to reach good European New Car Assessment Programme scores. The energy produced during the shock must be absorbed and no fracture of contactable parts should appear. To design the best solution, numerical finite element codes are used and predictability of the calculations is necessary to converge directly to the safest concept. This paper shows a great improvement in the calculation accuracy by modelling the behaviour of links between parts. Polymer rivet and snap behaviours are discussed and a methodology for samples is described. It is now possible to detect and to reinforce design in risk areas with crash simulations to avoid any breakage of the door panel assembly. Finally, a validation of the door panel is highlighted by comparing experimental results and numerical simulation predictions.