The inclusion of crashworthiness requirements in the development of modern automobiles involves many design tradeoff decisions. Sophisticated computer based simulation techniques help to solve structural analysis problems, bet they are only usedin sub-processes that translate a design into a physical product. This paper describes a methodology that captures knowledge about design for side impact crashworthiness, enabling a best practise process to be applied in future vehicle projects. Theimpetus for this research is the awareness that a great deal of design lead time and cost is wasted due to re-evaluation of design concepts following project team changes.The paper proceeds to highlight the significant advantages of the design methodology, these being that it: (1) indicates the scope for feasible component mechanical properties; (2) reduces the structure design lead time; (3) provides a scientificframework for decision making and cost tradeoff analysis; and (4) ensures valuable company expertise is retained and protected
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