CarCrashNet: A Large-Scale Dataset and Hierarchical Neural Solver for Data-Driven Structural Crash Simulation
Authors: Mohamed Elrefaie, Dule Shu, Matthew Klenk, Faez Ahmed
Abstract
Crash simulation is a cornerstone of modern vehicle development because it reduces the need for costly physical prototypes, accelerates safety-driven design iteration, and increasingly supports virtual testing workflows. At the same time, modeling structural crash mechanics remains exceptionally challenging: the response is governed by nonlinear contact, large deformation, material plasticity, failure, and complex multi-body interactions evolving over space and time on high-resolution finite-element meshes. In this work, we introduce CarCrashNet, a public high-fidelity open-source benchmark for data-driven structural crash simulation. CarCrashNet combines component-scale and full-vehicle simulations in a multi-modal format, including more than 14,000 bumper-beam pole-impact simulations with varying geometry, materials, and boundary conditions, together with 825 full-vehicle crash simulations built from three industry-standard vehicle models of increasing structural complexity: Dodge Neon, Toyota Yaris, and Chevrolet Silverado. To establish the reliability of the benchmark, we validate our open-source finite-element workflow based on OpenRadioss against both experimental crash data and the commercial solver Ansys LS-DYNA. We also introduce CrashSolver, a machine-learning model designed for full-vehicle crash prediction from high-resolution finite-element crash data. We further perform extensive benchmarking across the released datasets and evaluate CrashSolver against state-of-the-art geometric deep learning and transformer-based neural solvers. Our results position CarCrashNet as a foundation for reproducible research in structural simulation, crashworthiness modeling, and AI-driven virtual crash testing. The dataset is available at https://github.com/Mohamedelrefaie/CarCrashNet.
Full-vehicle crash simulations are computationally expensive, limiting their use in iterative design exploration. This work investigates learned hybrid surrogate models (MeshTransolver, MeshGeoTransolver, and MeshGeoFLARE) for predicting time-resolved structural deformation fields in an industrial lateral pole-impact benchmark. We evaluate whether neural surrogates can reproduce full-field crash kinematics with sufficient accuracy, spatial regularity, and structural plausibility for engineering interpretation. The proposed architectures combine local mesh message passing, geometry-aware global attention, and sparse contact-aware correction for autoregressive crash rollout. We compare mesh-based graph neural networks, attention-based geometric models, and hybrid architectures under a common training and hyperparameter configuration. The hybrid models capture both short-range structural interactions and long-range deformation patterns, while a sparse contact-aware variant assesses the effect of dynamic proximity interactions during rollout. On a 25-sample full-vehicle test set, the best hybrid model achieves a temporal mean root-mean-square error of 3.20 mm. While geometry-aware attention baselines are quantitatively competitive, qualitative side-view inspection shows they can introduce local spatial noise and deformation irregularities that complicate structural interpretation. In contrast, hybrid mesh-attention models provide the best balance between scalar accuracy, survival-space consistency, and physically interpretable displacement fields. These results suggest that crash surrogate assessment should combine global error metrics with downstream safety-relevant quantities and qualitative field inspection. The proposed methodology enables fast full-field predictions while preserving essential structural information for industrial crash-engineering analysis.
Gabriel Curtosi, Carlos Manuel Ruiz Ruiz, Fabiola Cavaliere +1
We introduce VZCrash, the largest publicly available dataset of real-world vehicle collision data featuring Inertial Measurement Unit (IMU) telemetry. The dataset contains more than 31,000 validated crashes and 158,000 negative samples, including hard cases and distractors. Each sample includes acceleration and angular velocity at 100 Hz, and GPS speed at 1 Hz. Events in VZCrash were captured by devices installed on a fleet of 73,010 commercial vehicles of different sizes driving in the United States over the span of several years. We also present an extensive experimental study enabled by the volume of the dataset. We first benchmark several different approaches, from a simple threshold-based heuristic to state-of-the-art deep learning models. Then, we present an experiment demonstrating the importance of scaling data to train high-quality crash detection models, and we show that scale is especially important when these models need to be deployed into a real-world environment.
Validating Autonomous Vehicles (AVs) requires exposure to rare, safety-critical scenarios, infrequent in routine driving data. Existing benchmarks address this by generating synthetic conflicts or mapping accident descriptions to abstract road geometries, failing to capture the topological complexity of real-world crashes. We introduce TRACE , a pipeline that automates the reconstruction of NHTSA crash reports into high-fidelity CARLA simulations by (1) retrieving site-specific OpenStreetMap data to preserve exact road topology, (2) leveraging Large Language Models to infer vehicles' initial state from road geometry and pre-crash maneuvers, and (3) generating simulation trajectories from semi-structured report data. Using this pipeline, we curated a benchmark of 52 diverse accident scenarios covering varied collision types, road topologies, and pre-crash maneuvers, providing a challenging open source resource for testing AV systems against real-world failures.