Passive safety is a well-known term. This term can be further categorized into different topics of the car passive safety, restraint systems, safety assistants (ABS, ESP, ASR, etc.). One of these topics is passive safety of the fuel system. Safety and tightness of the fuel system must be guaranteed even under non-standard conditions, for example a collision against a fixed obstacle. This issue is not often mentioned in the field of car safety. It is considered a standard. Passive safety of the fuel system is often ensured using various interesting technical solutions and devices, usually patented ones. The development of these solutions is supported by numerical simulations in different stages of development process. The doctoral thesis deals with impact loading of the plastic components of the fuel system, in particular Fuel Supply Module (FSM), which is mounted inside the fuel tank. The flange is the most important part of the fuel supply module from the car safety point of view. The flange closes FSM on the external side of the fuel tank. The thesis focuses on the finite element analysis of the complete or partial FSM, and the flange itself during impact loading. The main objective of this thesis are numerical material models, taking into account important aspects of the mechanical behavior of polymer materials during impact loading. There are a lot of ad hoc invented or standardized experiments described in this thesis. These experiments are used for estimation of the material parameters or comparison of numerical analysis vs real conditions, or tests. The solver LS-DYNA was mainly used for numerical simulations. The final results of this thesis brings new quantified knowledge about behavior of the Typical Semi-Crystal Polymer (TSCP), not only for impact loading. The practical part of this thesis defines new methodology for the numerical simulation approach of impact loading for FSM. This methodology is directly usable for new product development. A lot of numerical material models were developed and tested. The best results were achieved using numerical material model *MAT_24 with combination of *MAT_ADD_EROSION card. The limits and parameters for this numerical material model was estimated empirically during conducting experiments. The numerical material model SAMP-1 was partly solved in this doctoral thesis, but more detail study will be given in future works.

A Lagrangian finite-element model of the plunge phase of the friction stir welding process was developed to better understand the plunge. The effects of both modeling and experimental parameters were explored. Experimental friction stir plunges were made in AA 7075-T6 at a plunge rate of 0.724 mm/s with spindle speeds ranging from 400 to 800 rpm. Comparable plunges were modeled in Forge2005. Various simulation parameters were explored to assess the effect on temperature prediction. These included the heat transfer coefficient between the tool and workpiece (from 0 to 2000 W/m-K), mesh size (node counts from 1,200 to 8,000), and material model (five different constitutive relationships). Simulated and measured workpiece temperatures were compared to evaluate model quality. As spindle speed increases, there is a statistically significant increase in measured temperature. However, over the range of spindle speeds studied, this difference is only about 10% of the measured temperature increase. Both the model and the simulation show a similar influence of spindle speed on temperature. The tool-workpiece heat transfer coefficient has a minor influence (<25% temperature change) on simulated peak temperature. Mesh size has a moderate influence (<40% temperature change) on simulated peak temperature, but a mesh size of 3000 nodes is sufficient. The material model has a high influence (>60% temperature change) on simulated peak temperature. Overall, the simulated temperature rise error was reduced from 300% to 50%. It is believed that this can be best improved in the future by developing improved material models.