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I used an older CAD model (2020-10-13 Chassis) in the front bar collision scenario with point masses for the passengers, battery box, and bulkheads/dynamics.
Results
Case #1: Default Gusset Meshes
I started with a moderate element size of 20 mm (based off of Tommy’s mesh independence study) and used default mesh settings for the gussets.
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After running a simulation, the maximum deformation was only 47 nm. This seems unrealistic in a 5G crash scenario. The maximum combined stress in the beam elements was 361.4 MPa.
Case #2: Tetrahedral Gusset Meshes
The first change was to switch the gussets from rectangular elements to tetrahedral mesh elements. The element sizes were kept at 20 mm.
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