Crash Simulation

One speaks of a crash when highly dynamic, short-term stressing of components is involved. These are solved by over-special procedures (explicit calculations).

The term crash simulation originally comes from the automotive sector and aims to reduce the crash behavior of expensive prototypes in tests using virtual crash models, while at the same time taking into account the ever-increasing demands on vehicle safety.

Merkle & Partner Crashsimulation

The crash behavior of new vehicle models is examined and optimized in the computer at an early stage.

Optimal crash behaviour and weight reduction are often opposite goals. Crash simulations can be used here to find compromises between the lightest possible construction and a safe passenger cell. The number of costly crash tests is reduced, which also shortens development times.

In our crash simulations, we give special attention to the connection technology of the individual components, as well as the creation of the necessary material cards, also for exotic materials such as foams, fibre composites, wood, plastics.

Crash simulations on automobiles are now more of a standard investigation and no longer count as “Rocket Science”.

In addition to vehicle components or complete vehicles, we also investigate the crash behaviour of motorhomes with interiors as well as the behaviour of aircraft seats in the VIP area during hard landings. 

We are increasingly focusing on marginal areas, e.g.

  • Design of test chambers for testing high-pressure components, hoses, pump housings, hydrogen tanks, gas containers, pipelines
  • Containment, the bursting behaviour of discs, rotors, impellers, centrifuges, compressors, turbines
  • Building protection, bollards, trapping fences, security gates
  • Case simulations, e.g. if valves fall to the floor during assembly
  • Packaging simulations, i.e. the behaviour of packed components during transport
  • Explosion simulations, shock waves, electric arcs
  • Protection of cabins on commercial or construction vehicles, ROPS (Roll Over Protection System), FOPS (Fall Over Protection System)
  • Safety cages in motor sports

etc. that can be mapped with the same calculation methods, but require specific know-how.

For this purpose, we require in particular strain rate-dependent material parameters in unusual strain rate ranges, which we can determine together with partners even for very high strain rates.

Together with our partner Digimat we can also describe complex materials and composites by calculation.

We are currently working on the interaction of real human models from computer scans against external influences.

Further keywords in connection with crash or explicit simulations are:

  • Airbag folding and validation
  • Barriers
  • Burst analysis
  • Bursting of discs, rotors, grinding wheels, pump impellers, turbines 
  • Exhaust gas turbochargers
  • Fire
  • Bumper tests
  • Containment
  • Dummy Simulation
  • Strain rates
  • Drop-Tests
  • ECE R135
  • ECE R95
  • ECE R137
  • ECE R34
  • Explosion
  • FOPS
  • Front-/Rear/-Side-Impact
  • Pedestrian protection
  • Protection of buildings
  • Belt and seat tension tests
  • Homologation
  • Occupant protection
  • Integrated Crash-FE-Dummy-Simulation
  • Component tests
  • Head Impact
  • Material cards
  • Armoring
  • Bollards
  • Test chamber
  • ROPS
  • Sled tests
  • Safety fences
  • Safety cage
  • Transport simulation
  • Behaviour of packaged components during transport
  • Packaging simulation

The main focus of such investigations is safety. Are your safety precautions suitable to protect people from flying parts (containment) or to prevent people from being injured in case of an impact (vehicle crash, safety cell)? In second place is the resulting damage, which should be minimized (packaging, transport).

Contact our engineering office:

Stefan Merkle
  • +49 (0) 7321 9343-0


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