Sudeep Chavare

Deepak Akhare, Mohammad Amin Nabian, Corey Adams et al.

Automotive crashworthiness optimization remains a safety-critical challenge, requiring the management of large-scale nonlinear structural deformations and energy dissipation through iterative, high-fidelity simulations. While traditional finite element solvers are computationally prohibitive, emerging operator learning frameworks provide rapid surrogate predictions; however, applying them to industrial-scale crash analysis, where complex geometry, contact nonlinearities, and rapidly evolving transient deformation coexist, remains an open challenge. In this paper, we demonstrate that the GeoTransolver framework provides a viable solution for accurate, high-fidelity crash dynamics prediction at industrial scale. Benchmarked on complex bumper beam and full-vehicle crash datasets, GeoTransolver captures multi-scale geometric context and accurately resolves plastic deformation patterns as well as acceleration profiles at critical occupant locations. Beyond the architecture itself, we propose and systematically evaluate a suite of temporal prediction recipes, including one-shot, time-conditional, and autoregressive rollout strategies, demonstrating that the one-shot approach achieves state-of-the-art accuracy with significantly reduced training overhead and inference latency. As a secondary contribution, we introduce a Fast Low-rank Attention Routing Engine (FLARE)-based modification to the GeoTransolver attention backbone that reduces memory overhead by approximately 2x while further improving predictive accuracy for O(N) long-range, high-frequency transients, preserving the geometry-aware cross-attention strengths of the base framework. Our results highlight the practical viability of geometry-aware operator learning for high-fidelity surrogate modeling of complex, safety-critical automotive dynamics.

Mohammad Amin Nabian, Sudeep Chavare, Deepak Akhare et al.

Crashworthiness assessment is a critical aspect of automotive design, traditionally relying on high-fidelity finite element (FE) simulations that are computationally expensive and time-consuming. This work presents an exploratory comparative study on developing machine learning-based surrogate models for efficient prediction of structural deformation in crash scenarios using the NVIDIA PhysicsNeMo framework. Given the limited prior work applying machine learning to structural crash dynamics, the primary contribution lies in demonstrating the feasibility and engineering utility of the various modeling approaches explored in this work. We investigate two state-of-the-art neural network architectures for modeling crash dynamics: MeshGraphNet, and Transolver. Additionally, we examine three strategies for modeling transient dynamics: time-conditional, the standard Autoregressive approach, and a stability-enhanced Autoregressive scheme incorporating rollout-based training. The models are evaluated on a comprehensive Body-in-White (BIW) crash dataset comprising 150 detailed FE simulations using LS-DYNA. The dataset represents a structurally rich vehicle assembly with over 200 components, including 38 key components featuring variable thickness distributions to capture realistic manufacturing variability. Each model utilizes the undeformed mesh geometry and component characteristics as inputs to predict the spatiotemporal evolution of the deformed mesh during the crash sequence. Evaluation results show that the models capture the overall deformation trends with reasonable fidelity, demonstrating the feasibility of applying machine learning to structural crash dynamics. Although not yet matching full FE accuracy, the models achieve orders-of-magnitude reductions in computational cost, enabling rapid design exploration and early-stage optimization in crashworthiness evaluation.