Toyota Yaris 2010 Modification

In this project, I conducted an in-depth explicit dynamics study to optimize the mass of the Toyota Yaris 2010, a mid-size sedan model originally developed by the National Crash Analysis Center (NCAC) of The George Washington University under a contract with the FHWA and NHTSA of the U.S. Department of Transportation. The primary objective was to refine the Finite Element Analysis (FEA) model for a frontal impact crash test, simulating a rigid barrier collision per FMVSS-208 standards, with the aim of achieving significant weight reduction while preserving structural integrity. The optimization process entailed analyzing the existing design for load distribution, material utilization, and stress propagation throughout the vehicle’s frame. Leveraging advanced material selection techniques and structural reconfiguration, I focused on reducing redundant mass in critical components without compromising *torsional and flexural rigidity.* To accomplish this, I used a series of iterative simulations to assess the vehicle's deformation patterns, rigid body acceleration, and displacement metrics under impact conditions. Through this rigorous optimization study, I achieved a 14% reduction in kerb weight, enhancing the vehicle's overall efficiency and **crashworthiness.** The refined design demonstrated improved crash performance with lower peak rigid body accelerations and controlled displacement during impact, contributing to enhanced passenger safety and fuel efficiency. These results highlight the careful balance between weight efficiency and safety considerations in automotive engineering, aligning with industry goals for sustainable, high-performance vehicle design. This study contributes valuable insights into mass reduction strategies for mid-size sedans, potentially informing future vehicle design standards.