This paper describes a straightforward and effective development process to formulate a frontal end structure to meet the crash safety requirements. The process developed provides a progressive localized buckling behavior for maximum energy absorption. The design and analysis are implemented by using a finite element collapsible beam theory to predict the strength and mode of collapse of the front end components and subsystem. A simplified lumped mass-spring system is proposed for predicting crash performance using the various components characteristic. The springs used in the model representing major energy absorption components and their stiffness are analytically obtained from FEA beam code. The effects of the crash on occupant response are simulated by a MADYMO model. The final designs are experimentally verified using dynamic test of full scale structure. Correlation between analysis and test is good and the structure achieves the desired crush characteristics in crush length, peak, and mean loads. This process provides a rapid develop tool toward an efficient structure for frontal crash energy absorption early in the vehicle program.

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