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In this paper, the MDO analysis is applied to the design integration in terms of NVH and crash safety. Considering the difference of characteristics in these two fields, all the design variables are used to construct the response surfaces in the NVH analysis, while for crash safety analysis, these design variables are split into three groups, front, side and rear, to reduce the computational cost. Many of the structure performance indices in the NVH and crash safety fields are included as the constraints in the MDO analysis, which proves that the design integration of these two fields through MDO analysis is feasible. A comparison of crash safety optimization and crash safety-NVH MDO is done through a parallel-coordinate diagram. The difference provides the CAE engineers to find the guidance to modify the original design architecture.

Finite element dummy models have been more and more widely applied in virtual development of occupant protection systems across the automotive industry due to their predictive capabilities. H350 dyna dummy model [1] is a finite element representation of the Hybrid III male dummy [2], which is designed to represent the average of the United States adult male population. Lower extremity injuries continue to occur in front crash accidents despite increasing improvement of vehicle crashworthiness and occupant restraint system. It is therefore desirable to predict lower tibia injury numbers in front occupant simulations. Though lower tibia loading/index predictions are not studied as much as the FMVSS 208 regulated injury numbers, the tibia indices are injury criteria that need to be assessed during IIHS and Euro NCAP frontal offset occupant simulations. However during front crash simulations, it is very difficult to achieve good correlations or predictions of lower tibia loadings.