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Front under run protection device (FUPD) is a regulatory requirement for passive safety of N2 & N3 category vehicle. This device gives effective protection for small vehicles (M1 or N1 category) against under running of big vehicles (N2 & N3 category) in the event of a frontal collision. FUPD generally consists of the front under run protector (FUP) and its mounting structure. As the compliance load target for N3 category is high, the FUP required achieving regulation target need to have high rigidity. This increases its size and hence the weight, Increase in weight has impact on payload and cost. To curtail the weight of FUP, in general Aluminum with higher strength is in use, but use of Aluminum increases the cost. So the main challenge in FUPD design is to achieve the design with optimal system weight & cost.

This paper reinforces the importance of correlation between CAE Analysis of CAB Bridge and Vehicle test data. CAB Bridge is a structural assembly, bolted to the Frame of a Truck. The initial objective of the study was to evaluate the influence of particular design modification on CAB Bridge. To perform CAE calculations, two different iterations of Boundary & loading conditions, were established and executed using CATIA V5. During Post processing of CAE results, detailed data analysis and interpretation were performed. The results of CAE Analysis and Vehicle test data were compared, to identify the iteration that correlated better with Vehicle test data. The data analysis and interpretation guided in finding key observations and concluding that the Torsion case as the most important loading condition.