1. © Altair Engineering 2009 4-1
The CAE Driven Safety Development Process of the New
Ford Fiesta
Dr. Axel Haenschke
Technical Specialist, Ford Motor Company Ltd
Ford Werke GmbH, Köln, Germany
ahaensch@ford.com
Abstract
The new Ford Fiesta – the new global vehicle is the blueprint for future product
development.
The new small car range goes on sale in Europe, Asia and North America progressively
between 2008 and 2010. Sales in North America start in 2010. In Europe, Fiesta is being
built in Cologne, Germany and Valencia, Spain. Outside of Europe, production will be in
Nanjing, China, Rayong in Thailand and Cuautitlàn in Mexico.
The new Fiesta is about premium feel of a larger car, delivers a new level of safety, driving
quality and efficiency. The new Fiesta will be a great contribution towards sustainability and
cost effective motoring.
The first thing to notice is the design, but the vehicle performance and body structure
attribute behaviour are the specific highlights to point out in this presentation. The attribute
performance is not based on coincidences; the performance is a result of state of the art
engineering work. Especially the safety performance in EuroNCAP:
• 5 star adult occupant rating
• 4 star child occupant rating
• 3 star Pedestrian Protection
is the result of state of the art tools and methods of the Ford CAE development process.
These CAE engineering tools and methods are the major focus of the presentation, e.g.
• the CAE safety model database
• the material database
• the use of HSS and mapping tools for CAE recognition of material forming history
The safety CAE tools, methods and development process are strongly driven by the Altair
Hyperworks environment. The results of the process are shown with several examples.
Keywords: Crashworthiness, HyperWorks, RADIOSS
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2. May 14 2009
The CAE Driven Safety Development Process of the new Ford
Fiesta
A. Hänschke Ford Werke GmbH, Köln, Germany
M. Spurling Ford Motor Company Limited, Dunton, United Kingdom
R. Santos TECOSIM Technical Simulation Ltd
Altair HyperWorks Technology Conference
May, 14th, 2009
Heritage Motor Centre
Gaydon, Warwickshire
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-2

3. 14th May, 2009
Agenda
• The New Ford Fiesta
• Safety Requirements and Achievements
• Structural and Safety Strategy
• CAE Development Process
• Questions & Answers
Ford Fiesta – CAE Driven Safety Process
3
14th May, 2009
The New Fiesta
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-3

4. 14th May, 2009
European Crash Sign-off Modes – High and Low Speed
Full Frontal Rigid
Vehicle = 48.3 kph & 56 kph
Thatcham / GDV 10deg Rigid
Vehicle = 15 kph
Side Pole Rigid
Vehicle = 29 kph
Thatcham / GDV 10deg Rigid
Barrier = 15 kph
Full Rear Rigid
Barrier = 38 kph & 50 kph
40% Offset Deformable (L&R)
Vehicle = 56 kph & 64 kph Side Deformable
Barrier = 50 kph
Fuel Filler Rear Deformable
Barrier = 80 kph
70% Offset Deformable (L&R)
Barrier = 80 kph
Various Adult
& child head,
leg-form and
thigh
pedestrian
impacts
Safety Requirements
14th May, 2009
5-star EuroNCAP rating
Final ratings
Safety Achievements
1E Thatcham Insurance rating
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-4

5. 14th May, 2009
EuroNCAP High Speed Crash Films compared to CAE
EuroNCAP Front Offset Impact
Safety Achievements
EuroNCAP Side Impact
14th May, 2009
• DP600 front rails with TWB front section to
achieve an efficient crush followed by bend and
counter-bend collapse strategy
• A/B Pillars hot-stamped from UHS Boron Steel
Structural and Safety Strategy
• DP600 rear side rails optimised for
energy absorption in 80km/h crash mode
• Safety cell for fueltank survival space
and door openability post test
• Low velocity “vertical” B-Pillar intrusion
profile
• Limit intrusion into the occupant cabin
• Prevent rocker panel rotation
• Transfer load through the underbody
High Speed Impact
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-5

6. 14th May, 2009
Structural and Safety Strategy
Low Speed Impact
• Hood controlled folding to avoid
damage to other parts
• Lower leg stiffener optimisation
to avoid cooling pack damage
• Strong shotgun closing
plate
• Fender bracket with
integrated headlamp
catcher
• Headlamp housing
controlled failure
• Rear/Front bumper
beam and crash cans
fitted and optimised
14th May, 2009
“up front” CAE Support
5dr upper structure (template)
714 715
202
202.1211
605
702
703
704
705.2 706.1
707
708
709
710
712 713
714 715714 715
202
202.1211
605
702
703
704
705.2 706.1
707
708
709
710
712 713
Master Sections
Parametric Concept Geometry to Support early Attribute Assessments
5dr B-Pillar proposal
and Design scan
Top Hat FEA-Model
merged with Platform
FEA-Model
CAE Development Process
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-6

7. 14th May, 2009
The Modular Safety CAE Approach
LMV_BIW
Dashboard_RHD/LHD
Body In Prime
Front Doors
Rear Doors
DoorTrims
Body Closures
Loudspeaker
Front BumperBeam
Rear BumperBeam
Front BumperFacia
Body Exteriour
Rear BumperFacia
GOR
Cockpit Structure
HVAC
Interiour Trim
Body Interiour
IP-Assembly
Front Seats
Rear Seats
Front Subframe
Rear Subframe
Front Strut & Knuckle
Chassis
Steering Column
Steering Gear
PedalBox & Booster
Tire & Wheels
ABS Modul
Fuel System
FE_Solver Radioss
LoadCases
Safety
PreProcess
PostProcess
Barriers
Dummies
Window Regulator
Hood
Liftgate
Hinges
Headlamps / FogLamp
Batterie Brackets
SAV_BIW
1000500
Energy
LMV_BIW
Dashboard_RHD/LHD
Body In Prime
Front Doors
Rear Doors
DoorTrims
Body Closures
Loudspeaker
Front BumperBeam
Rear BumperBeam
Front BumperFacia
Body Exterior
Rear BumperFacia
GOR
Cockpit Structure
HVAC
Interior Trim
Body Interior
IP-Assembly
Front Seats
Rear Seats
Front Subframe
Rear Subframe
Front Strut & Knuckle
Chassis
Steering Column
Steering Gear
PedalBox & Booster
Tire & Wheels
ABS Module
Fuel System
FE_Solver Radioss
LoadCases
Safety
PreProcess
PostProcess
Barriers
Dummies
Window Regulator
Hood
Liftgate
Hinges
Headlamps / FogLamp
Battery Brackets
SAV_BIW
1000500
SAV_BIW
1000500
Energy
CAE Development Process
14th May, 2009
Fully Automated
Data Mapping Tool
MAPIT*
Projects forming CAE material
properties data onto full vehicle
models using mesh independent
algorithms
* MAPIT is a Ford Motor Company in-house developed software tool
Component thickness
distribution is extracted
Component residual plastic
strain distribution is extracted
Pre-Strain and
thickness distribution
included into the full
vehicle simulation
The work hardening affects of Dual Phase
steel are significant and must be included!
Material History in Crash Simulation / Mapping
CAE Development Process
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-7

8. 14th May, 2009
Extensively engineered using CAE methodologies
• Crash simulation models have over 1,000,000 elements.
• Super computers are used to run the models, which can take 24 multi-processors over 20hrs to complete!
14th May, 2009
Thanks for
listening
Questions & Answers
© Altair Engineering 2009 The CAE Driven Safety Development Process of the New Ford Fiesta 4-8
Click here to contact Altair