Crash Box Simulation – Crashworthiness Study Using LS-DYNA

This project explored the fundamentals of crashworthiness by analyzing how an automotive crash box absorbs impact energy during a collision. A crash box functions as a deformable structural element similar to a controlled crumple zone designed to dissipate energy and reduce the forces transmitted to the vehicle’s main body structure and passengers.

For this Level 1 simulation, I developed a finite element model in LS-DYNA to evaluate the crash box response during a frontal right-side impact. The study involved defining material properties, contact interactions, impact boundary conditions, and monitoring deformation patterns, energy absorption, and load paths throughout the event. The results highlighted how geometrical design and material behavior influence structural collapse mode and energy-management performance.

This project provided valuable hands-on experience with LS-DYNA’s explicit dynamics environment and introduced core principles in crash energy management, deformation modes, and structural safety.

Skills: LS-DYNA, Explicit Dynamic Analysis, Crashworthiness, Impact Simulation, Structural Deformation, Energy Absorption, Finite Element Modeling