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Robustness analysis of a vehicle front structure using statistical approach

In this study, a process for assessing the robustness of designs has been presented, and the results are discussed using front structures of a vehicle FE model as an example. Statistical approaches have been introduced in order to assess the robustness of the structural design. Dozens of numerical simulations have been conducted taking into account uncertainties in input parameters such as spotweld failure criteria. The scatters in input parameters and the resultant deformations are statistically analyzed using a tool DIFFCRASH in order to capture the timing and location of bifurcations, and to understand the mechanisms inducing scatters in results. Spotweld strength of detected bifurcation triggers have been modified as countermeasure, and reduction of scatters by suppressing bifurcations has been confirmed.