This paper discusses novel numerical techniques for studying the damage to automotive safety components in carbon fiber reinforced polymer (CFRP) deployed in the automotive industry to protect passengers, high voltage batteries and powertrains from rear impacts. The idea proposed in the manuscript is to use Newmark’s methodology with the FEM for the numerical description of the explicit dynamic model of the components facing the standard impactor, following the Euro NCAP protocol. Using an explicit dynamic Radioss rear crash box, we have successfully demonstrated normal behavior for CFRP materials, where the value of kinetic energy is close to the theoretical value. Moreover, the simulation provides a behavior consistent with previous successful studies because the maximum dynamic time is the same as the total damage (0.10 ms).

LGP cylinders are necessary for fuel storage and home heating. To avoid material and human risk, it is essential to maintain their structural integrity. Extensive mechanical research studies and physical tests are necessary for its design. This paper investigates the mechanical performance of the storage capacity of an LPG cylinder under static loading. The authors integrate and adapt IGA with the T-Splines function for geometry modeling and numerical analysis in the context of linear elasticity. The main focus is on the strains and stress numerical results. The obtained results are examined and verified with the FEM in Abaqus/Standard. The results found show that the storage capacity of a single cylinder is equivalent to 15 empty cylinders. This study also demonstrates that the T-Splines method is a promising alternative for numerically analyzing the mechanical structure performance of LPG cylinders, particularly in energy storage issues.

In this paper, we propose a new approach for numerically simulating the growth of cracks in unidirectional composite materials, termed extended isogeometric analysis, evaluating the maximum stress intensity factor and T-stress. To validate our approach, we used a small anisotropic plate with two edge cracks, beginning with formulating the governing equations based on the energy integral method, Stroh’s Formula, and the Elastic Law describing the behaviour of anisotropic materials, while considering boundary conditions and initial states. A MATLAB code was developed to solve these equations numerically and to post-process the tensile stress and the stress intensity factor (SIF) in the first mode. The results for the SIF closely match those obtained using the extended finite element method (X-FEM), with a discrepancy of only 0.0021 Pa·m^0.5. This finding underscores the credibility of our approach. The extended finite element method has demonstrated robustness in predicting crack propagation in composite materials in recent years, leading to its adoption by several widely used software packages in various industries.

In the context of the automotive industry, this paper proposes an enhancement of the numerical simulation using FEM and performing material choosing with the Ashby method for automotive brake discs, using the symmetric shape of the disc. Automotive braking involves the dissipation of kinetic energy through heat generation due to friction, a physical phenomenon that alters the mechanical properties of brake discs. This prompts automotive development engineers to investigate new materials capable of absorbing heat while maintaining their mechanical properties. A thermomechanical study of a ventilated front brake disc has successfully demonstrated a good performance of cast iron because the equivalent stress is significantly lower than the elastic limit, with a margin of approximately 73 MPa. Compared to validated results extracted from the state of the art, the adopted methodology gives more realistic results with minimum CPU requirements, where the total time of calculation is around 40 min. More than that, the results are suitable to be used for studying durability and other properties like mechanical impact and fatigue.

In automotive industry, numerical crash analysis is a mandatory test before going to tooling kick off phase, this test makes engineers able to predict the vehicle behavior face to side, frontal, and rear impacts. Where EURONCAP protocols have become international standards for vehicle safety ranking. The coherence between physical test and FEM test has become the main challenge for making simulations more realistic, with ensuring optimization of automotive modeling and the best representation of physical sensors. This communication proposes an enhancement of FEM modeling of piezo-electric sensors (Accels) for acceleration measurement in object to get the deceleration data under impact using RBE2 and solid FEM properties in object the avoid deviations causing data errors. Moreover, a verification test has been able to validate the proposed approach where the curve of acceleration is the same for solid representation of accelerometer and aligned mesh with X, where with using deviation of the edge the result changed.

This study presents a hybrid Non-Uniform Rational B-Spline (NURBS) methodology for the geometric reconstruction of topology-optimized structural components. NURBS are employed exclusively as a post-processing tool; all structural analyses are performed using standard finite elements (SOLID187 elements, ANSYS Mechanical R19.2), and isogeometric analysis (IGA) is not used. The methodology is validated on an Al 6061-T6 electric scooter neck under a 600 N static load. Two SIMP optimization iterations followed by a hybrid NURBS reconstruction reduce the component mass from 1.247 kg to 0.531 kg, achieving a 57.4% mass reduction. Finite element re-validation of the reconstructed geometry yields a maximum von Mises stress of 126.45 MPa (safety factor, SF = 2.18, exceeding the 2.0 requirement), a maximum deflection of 2.31 mm, and a first natural frequency of 127 Hz. Mesh convergence between the 2.5 mm and 1.25 mm refinements is Δ = 0.90%. Relative to the direct SIMP output (201 MPa), NURBS reconstruction reduces the peak stress by 37%, demonstrating that geometric post-processing is not a neutral step but a critical determinant of structural performance. Both fully automated STL reconstruction and edge-based NURBS reconstruction failed for this geometry class due to non-manifold topology and patch discontinuities, respectively. The proposed hybrid region-decomposition approach is the only method that has produced a watertight, FEA-compatible CAD model.