This paper discusses the methods and techniques in designing a mid-size Aluminum vehicle front end for crashworthiness. Aluminum was used in place of steel in order to reduce weight, hence the fuel consumption, this change allowed a reduction of about 53% in total weight of BIW as compared to steel one with same size and crush strength. For maximum energy absorption, concept of progressive localized buckling of vehicle components was used. To develop the most efficient energy absorbing cross-sections for front end components a computer beam code SECOLLAPSE is used. Cross sectional properties (Peak and Mean loads) of these sections were compared to the steel cross sections. Front end components then modeled and analyzed by using the non linear Finite Element crash code V-CRUSH and the final design was verified by comparing with existing steel design of similar configuration. Testing of this structure and its various front end component is under way and results will be presented in a later study.

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