Crashworthiness Analysis using HyperMesh and Radioss

Crash Worthiness Analysis using HyperMesh and Radioss

  • 0% EMI Option Available
  • Pre-requisites : Strength of Materials and Finite Element Analysis
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A Quick Overview

Crashworthiness is a domain in which you can understand the structural integrity of any vehicle when it is subjected to a crash. A sub-domain of this will deal with passenger safety as well as pedestrian safety. This course focuses on the solver known as RADIOSS which is used in the frontal, side, and roof crush analysis.

In this course, you will learn about meshing using HyperMesh and RADIOSS. A key focus in Auto and aero industries is crash testing and this course sets you up with the right skill to get a leg in the industry.  At the end of this course, you will be able to set up cases of any explicit simulation, you will be able to debug the errors, and finally post-process the result. 


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1Basics of Crashworthiness Physics, FEA Concepts and CAE Process

The first module you learn will learn about different types of analysis, the difference between Implicit and Explicit analysis, different non-linearities and along with this you will also bust the myth that ‘strong structure equates safe structure’ by teaching you about:

  • Meaning of crash safety for a vehicle

  • Law of conservation of energy applied to a car crash

  • Basic concepts of FEA such as linear-nonlinear, static-dynamic, Implicit- Explicit analysis, their differences and the guidelines on how to choose a method for a given FEA problem

2Introduction to HyperMesh

HyperMesh is one of the most popular Finite Element Preprocessor used to generate meshes

of complex models. In this module, you will learn the GUI of HyperMesh, various elements available in FEA like 1D, 2D and 3D elements, how to choose the element depending on the geometry by covering topics such as:

  • Overview of Pre-Processors and their importance in FEA Processes

  • Primary introduction to GUI of HyperMesh, toolbars and basic operations

3Geometry Editing in HyperMesh

Learning to mesh geometries is an important step in performing FEA. Therefore, we will extensively cover the topic by which the students can understand, geometry clean up, tools available for geometry cleanups, 

  • Using an edited geometry to generate mid-surface and appropriate 2D mesh with regards to mesh flow, trias and mesh size, by various methods

  • Using the geometry tools to clean up the distorted geometry

4Meshing – 1D, 2D & 3D and Mesh Quality Check

In this section, you will learn what is 1D, 2D, and 3D meshing, what is mesh quality and how to improve them and then exporting the meshed model to the specific solver.

  • Using an edited geometry to generate mid-surface and appropriate 2D mesh with regards to mesh flow, trias and mesh size, by various methods

  • Using the geometry to create a 3D mesh using various methods

  • Meaning of mesh quality and ways to control and improve it

  • Types of 1D elements, their specifications, and creation

  • Exporting a meshed model from HyperMesh in the specified solver format

5Introduction to Radioss

In this section, you will learn what is an Explicit Solver, what is an engine file and a starter file and their significance and also what is an out file and how to read this out file.

  • Overview of Radioss- An Explicit FEA solver for crashworthiness

  • Essential Radioss input files, their significance, and format

  • Overview of output files and their significance

6Element Properties and Materials

In this section, you will learn about the various element formulations available for different types of elements in the Radioss and their applications, how to assign thickness for the component and also you will understand various parameters available in the property card and their significance. 

Similarly, you will also learn various material cards available in Radioss and their use cases along with their failure criteria.

  • Application of thickness and dimensional properties, integration points for 1D, 2D and 3D elements

  • Study and application of concepts such as material intrinsic properties, failure criteria, non-linearity, plasticity, and hyper-elasticity into a material model

7HyperCrash, HyperView and HyperGraph

In this section, you will learn a new application that is developed by Altair exclusively to set up the crash simulations and along with this, you will be learning the GUI of Hypercrash. You will also be introduced to Hyperview and HyperGraph where you will learn how to post-process the simulation results

  • Introduction to HyperCrash, a specialized pre-processor for Radioss

  • Introduction to HyperView and HyperGraph as post-processing tools in the FEA process

8Interface (Contact) Modelling

Interface modelling will be a complex topic that you can find in any solver. Here you will learn what is a contact and how it works, what are the different parameters you need to look into while defining a contact in a model, what are the different types of contacts and their use cases. 

  • Concepts of an interface between given components, penalty formulation method, contact stiffness, gap, penetration, interference, and tied interfaces

  • Creation of various types of interfaces and removing any errors or interferences

9Boundary Conditions Setup

In this section, you will understand how to set up a proper boundary condition for any given simulation, what are the different types of loading conditions and different types of joints available in Radioss

  • Setup of static and dynamic loading conditions such as velocity, acceleration, a constraint on degree of freedom, rigid walls, spot welds, and seam welds

10Simulation Control

In this section, you will learn about the concept of the time step and how it can be optimized to increase the speed of the simulation and also the concept of mass scaling. You will also understand the various control cards available in Radioss and their use cases.

  • Control of simulation in terms of the time step, accuracy, run time, types of outputs

11Checks and Debugs

In this section, you will the various check you to do before running the simulation and also you will understand how to debug a simulation along with its approach 

  • Checking and debugging any errors in the model using diagnostic methods

12Airbag and its Modelling in FEA

In this section, you will exclusively learn about the Physics of an airbag in crash scenarios and how to model them in Radioss. You will be learning about two types of Airbags ( with vent and without vent ) 

  • Concept of an airbag in FEA, its modelling methods and challenges with an example

13Occupant Injury Criteria

In this section, you will learn about how the injury criteria are calculated in the actual crash test environment and how it affects the rating of the vehicle. You will also learn about the dummy standards that are used in crash testing. 

  • Various occupant injury criteria currently being considered while determining the crashworthiness and safety performance of a car

14Crashworthiness Standards

In this section, you will learn about the standards followed in different ENCAPs 

  • Study of basic elements of most popular crashworthiness standards, the criteria used while determining the crashworthiness performance and ways to measure this in the FEA model

Projects Overview

Frontal Crash


    • In this project, you will set up the case for the frontal crash simulation from scratch. 
    • You will also work on post-processing the results and report the Sectional forces at different places in the vehicle to understand force flow, Dashwall intrusion, force at the bumper in the event of a crash and also the peak acceleration at the Rocker.

    Side Impact


      • In this project, you will set up the case for the side crash simulation from scratch.
      • You will also be post-processing the results and capturing the sectional forces at different places in the vehicle to understand force flow, B-pillar & fuel tank intrusions and the peak velocity at the door.

      Roof Crush


        • In this project, you will set up the case for the roof crash simulation from scratch. 
        • You will post-process the results and capture the overall strength of the roof. You will also repair the rigid bodies and positioning the impactor.


        • Students in Mechanical, Aerospace or Automotive engineering
        • Freshers looking to gain project experience on HyperMesh, Radioss and FEA
        • Professionals seeking opportunities as CAE Modellers, CAE Analysts ( with modelling experience ) in crash and safety domain in any industry
        • This course opens the gates to the world of safety in automobiles, methods of implementing the safety systems, and validation of the results.



        HyperMesh is a software from Altair. It contains the RADIOSS solver that is used extensively in this course.


        HyperCrash is an inbuilt software that comes with hyperMesh, which is specially designed for setting up models for car crash simulations.

        Download syllabus

        Crashworthiness Analysis using HyperMesh and Radioss

        Download Syllabus

        Flexible Course Fees

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        2 Months Access


        Per month for 3 months

        • Access Duration : 2 months
        • Mode of Delivery : Online
        • Project Portfolio : Available
        • Certification : Available
        • Email Support : Available
        • Forum Support : Available

        Lifetime Access


        Per month for 3 months

        • Access Duration : Lifetime
        • Mode of Delivery : Online
        • Project Portfolio : Available
        • Certification : Available
        • Individual Video Support : 12/month
        • Group Video Support : 12/month
        • Email Support : Available
        • Forum Support : Available
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        • Dedicated Support Engineer : Available

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        Frequently Asked Questions

        1Who are the instructors and what is the learning process?

        Our instructors are industry experts working in Fortune 500 companies. We partner with them to deliver the lectures online. You will be given access to recorded content and assignments each week.

        2Are there any prerequisites for this course?

        You should be pursuing or have graduated with a B.E/B.Tech in Mechanical or Automotive Engineering.

        3What kind of support I can expect? What if I have doubts?

        Our support system is amazing!. You can read our reviews on Google to see this. We focus on one-on-one support which no one else does. We will communicate with you through videoconferencing, WhatsApp messages/calls, individual online sessions and also in person. Doubts and queries are addressed by a dedicated support engineer who is assigned to you to walk you through your problem areas and clarify any queries that you may have.

        4How is this different from what I learnt in college?

        Our courses are crafted after consultation with industry experts. This gives you the opportunity to apply what you have learned only as theory and work on projects that will give you a leg up in your career aspirations - be it an MS admit, a new job or growth within your organization. This course will help you bridge the gap between academia and industry and get you market-ready.

        5What advantages will I gain by taking this course?

        You will have an edge over your peers by working extensively on industry-relevant projects, practice on tools and software that will set you apart and help you in getting ahead of the competition. Our course will strengthen your portfolio to get better grants and scholarship opportunities for MS Admits, explore options in Research & Development, and land that much-coveted job in top core companies. 

        6How much time does it take to solve a frontal crash analysis?

        It depends on your system configurations, usually it will take 1 hour to 1.5 hours to solve.

        7Is the full version of HyperMesh software required?

        Altair provides a student version of HyperMesh software which has a license period of 1 year. The license provided is node-locked.

        8Is crashworthiness too difficult to understand?

        If you know how the basic simulation works, then it will be very simple to complete this crashworthiness course.

        9How much time should I spend each day to complete the course?

        A dedicated 2 hours of time is more than enough to understand the concepts, noting the concepts down and performing the challenges.

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