For more than 20 years prototypes from Courage Competition have been successfully competing with those of global OEMs at Le Mans. To maintain that competitiveness, the independent manufacturer, based in Le Mans, employs software simulation to reduce lead times, lower costs, and design better-performing race cars.
Courage used Pam-Crash by ESI Group to study the behavior of the nose of its C60 car that will compete in the next 24 Hours of Le Mans. The analysis was complex because the nose is made of composite materials. The nose breaks into tiny pieces, unlike metals that deform under impact. Pam-Crash let Courage meet new more stringent frontal crash test regulations while reducing the nose's weight by 75%. Simulation results were within 3% of physical test results.
Using various software simulation tools, engineers analyzed every composite component of the new C60. The result was a 15% weight reduction though load requirements in the new regulations are much higher.