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10th European LS-DYNA Conference

Würzburg, 2015

A Fabric Material Model with Stress Map Functionality in LS-DYNA
T. Borrvall (DYNAmore Nordic)
C. Ehle, T. Stratton (Autoliv OTC)
Material 34 (MAT_FABRIC) in LS-DYNA is the material model of choice for fabrics when simulating airbag deployment in the automotive industry. Over the years, the model has been subjected to continuous robustness improvements and incorporation of important application features and today it comes in several forms and with an extensive set of parameters. The state-of-the-art modelling approach is to use the FORM=14 option which allows for ...
A Finite Element Investigation Into the Continuous Induction Welding of Dissimilar Material Joints
M. Duhovic, J. Hausmann (Institut für Verbundwerk­stoffe)
P. L´Eplattenier, I. Caldichoury (LSTC)
Continuous induction welding is an advanced material processing method with a very high potential of providing a flexible, fast and energy efficient means of joining together thermoplastic composites to themselves and metals and alloys. However, selection of the processing parameters and optimization of the process is very difficult as it involves the interaction of up to four differen t types of physics. In addition, ...
A Graphical User Interface for Simulating Resin-Transfer-Molding Combining LS-DYNA and OpenFOAM
M. Wagner, M. Martins-Wagner (OTH Regensburg)
A. Haufe, C. Liebold (DYNAmore)
The paper describes parts of the joint research project Swim-RTM including several industrial and academic partners. Its goal is to combine LS-DYNA and the open-source fluid-dynamics solver OpenFOAM® to simulate the production process for fiber reinforced plastics, particularly the resin-transfer-molding (RTM) process. In this process, the layers of dry fabric (uni-directional or woven) are formed in the mold (draping) and then filled with ...
A New Feature to Model Shell-Like Structures with Stacked Elements
T. Erhart (DYNAmore)
A computational method for the numerical simulation of stacked shell-like structures will be presented. These types of plane load-bearing components possess a thickness which is small compared to its other (in-plane) dimensions and physical properties vary in thickness direction in distinct layers. Such materials are made from two or more constituent materials with different physical or chemical properties, that when combined, produce a material ...
A Numerical Investigation of Turbulent Flow in Circular U-Bend
A. Miloud, M. Aounallah, O. Imine, M. Guen (University of Science and Technology of Oran Algeria)
A numerical investigation of Turbulent flows through a circular 180° curved bend with defined as the bend mean radius to pipe diameter for a Reynolds number of 4.45×104 is presented in this study . The computation domain is performed for a U-Bend with full long pipes at the entrance and at the exit. Two turbulence models were tested in this work.
A Variable Finite Element Model of the Overall Human Masticatory System for Evaluation of Stress Distributions During Biting and Bruxism
S. Martinez, J. Lenz, Prof. K. Schweizer­hof (Karlsruhe Institute of Technology)
H. Schindler (University of Heidelberg)
Simulating the masticatory system during chewing, clenching and bruxism, requires the model to capture the dynamical behavior of its different components: the mandibula and maxilla, the temporomandibular joint (TMJ) including the articular disc and the surrounding cartilage layers, the teeth, the periodontal ligaments (PDL), and the muscles
A Weight Balanced Multi-Objective Topology Optimization for Automotive Development
N. Aulig, S. Menzel (Honda Research Institute Europe)
E. Nutwell (Ohio State Uiversity)
D. Detwiler (Honda R&D)
ACP Process Integrated 3B Forming Optimization
A. Farahani, D. Mittal (Engineering Technology Associates)
J. Shaw (US Steel)
The automotive and steel industries have several initiatives such as the development of 3 rd Generation Advanced High Strength Steels (AHSS), the Nonlinear Strain Path Project and the A/SP AHSS Stamping Team Projects. These initiatives are efforts to expand the forming design space with AHSS to enable increased part complexity, which will allow AHSS to be incorporated into more vehicle components and enable mass reduction. The proposed approach ...
Agile Dummy Model Development Illustrated by Refinement Activities of the WorldSID Shoulder Model
R. Brown, G. Stokes (Jaguar Land Rover)
U. Franz, S. Stahlschmidt (DYNAmore)
The Agile Software Development is a method that promotes adaptive planning, evolutionary development, early delivery, continuous improvement, and encourages rapid and flexible response to changes. This method is established in the development of software and influences also many other development processes. The employees at DYNAmore are developing dummy models together with a consortium of car companies since decades. The models are used world ...
An Advanced Identification Procedure for Material Model Parameters based on Image Analysis
L. Peroni, M. Scapin, C. Fichera (Politecnico di Torino)
Inverse methods for the material strength model calibration are widespread techniques, which allow taking into account for the actual strain, strain-rate, temperature and triaxiality fields inside the specimen. An optimization procedure generally starts from experimental measurement of force-stroke time history and is based on the minimization of the difference between experimental and numerically computed quantities. In this work, the strength ...
An Assessment of ALE Mapping Technique for Buried Charge Simulations
I. Kurtoğlu (FNSS Savunma Sistemleri)
In this work, the effects of ALE mapping technique developed by LSTC [1] are investigated for buried charge simulations. Before mapping studies, a mesh sensitivity study is performed for the pure ALE simulations to investigate the effect of 3D mesh size on the impulse. The ALE mapping is performed from a 2D axisymmetric model to full 3D model.
An Investigation of AL7075-T651 Plate Perforation Using Different Projectile Nose Shapes
B. Balaban, İ. Kurtoğlu (FNSS Savunma Sistemleri)
In this study, the ballistic resistance of monolithic and double-layered plates made of AL7075-T651 are evaluated using the non-linear finite element code LS-DYNA®. Plate simulations are carried out using 20 mm diameter, 197g mass hardened steel projectiles with blunt and ogival nose shapes. Penetration simulations of 20 mm monolithic plates made of AL7075-T651 are performed with both Lagrange and ALE methods and the results are compared with ...
An Investigation of Modeling Approaches for Material Instability of Aluminum Sheet Metal using the GISSMO Model
G. Falkinger (Leichtmetallkompetenz­zentrum Ranshofen LKR)
P. Simon (AMAG Rolling)
The most generally accepted tool for the assessment of formability of sheet material up to the present date is the forming limit diagram (FLD). It allows the identification of critical areas in a sheet - forming simulation where critical thinning or the appearance of cracks is to be expected. The FLD is determined experimentally in Nakajima tests and is widely used in the design of sheet forming processes . However it is known that the ...
Analysis of Unsteady Aerodynamics of a Car Model with Radiator in Dyna­­mic Pitching Motion using LS-DYNA
Y. Nakae, J. Takamitsu, H. Tanaka, T. Yasuki (Toyota Motor)
This paper describes the numerical analysis of unsteady aerodynamics of a radiator mounted car model in dynamic pitching motion using LS-DYNA ICFD solver. Large-Eddy simulations with ALE method and porous media modeling were performed to clarify the unsteady aerodynamic forces acting on cars with engine compartment in dynamic motion.
Application of the SPH Finite Element Method to Evaluate Pipeline Response to Slope Instability and Landslides
A. Fredj, A. Dinovitzer (BMT Fleet Tech-nology)
M. Sen (Enbridge Pipelines)
Buried pipelines operating on active slopes can be subject to lateral and axial loads resulting from slope instability and landslides. The techniques to predict pipeline displacements, loads, stress or strains are not well described in design standards or codes of practice. Finite element analysis based soil-pipe interaction simulation has developed in recent years and is proving to be a useful tool in evaluating the pipeline behavior in ...
Assessment of Motorcycle Helmet Chin Bar Design Criteria with Respect to Basilar Skull Fracture using FEM
S. Farajzadeh Khosroshahi, M. Ghajari (Imperial College London)
U. Galvanetto (University of Padova)
Statistical studies showed that the chin bar of full-face helmets is the region with the highest number of impacts. In an Australian research, fifty percent of severe impacts took place to the front of the helmet and forty percent of these resulted in Basilar Skull Fracture (BSF). There are two standards, which include criteria for assessing the performance of the helmet’s chin bar, Snell M2015 and ECE 22.05.
Book of Abstracts.pdf
CAE Analysis of Passenger Airbag Bursting through Instrumental Panel Based on Corpuscular Particle Method
Y. Feng, M. Beadle (Jaguar Land Rover)
The safety regulation requires that passenger airbag (PAB) to deploy into working position in time without causing any fragmentation of its surrounding structure. Due to the significant load of airbag deployment and its complex unfolding process, it is always a challenge to design a PAB system which enables airbag safely bursting through instrumental panel. A CAE based approach has been developed at Jaguar Land Rover (JLR) to lead the passenger ...
CAE as a Service as Cloud Platform for the Full LS-DYNA Simulation Process
A. Geiger, K.-H. Hierholz, C. Neimöck (T-Systems)
Mit CAE as a Service stellt T-Systems eine Cloud-basierte Lösung für den gesamten CAE Prozess vom Infrastruktur- bis zum Softwarelayer mit dynamisch skalierbarem Durchsatz und Leistungsfähigkeit. Use cases sind u.a. (a) HPC Spitzenlastabdeckung für Durchsatz- und Problemgrößen-Peaks, (b) Bereitstellung des vollständigen CAE Prozesses mit Pre-/Solver-/Postprocessing und Simulation Data Management als Service, (c) Bereitstellung von sicheren und ...
CAE Validation Study of a Side Window Impact using Plexiglas Materials
D. Lopez Ruiz (Tecosim Technische Simulation)
A. Rühl, Prof. S. Kolling (THM Giessen)
E. Ruban, B. Kiese­wetter, S. Ulzheimer (Evonik Industries)
An experimental and numerical study regarding the head impact on a side rear window was performed. Based on several years of material development and manufacturability (Evonik Industries AG), the expert knowhow in material testing and LS-DYNA material implementation (Giessen Institute of Mechanics and Materials) and the CAE user experience (TECOSIM Technische Simulation GmbH) and in closer cooperation between all parties, it was decided to start ...
Calculation and Validation of Material Tests with Specimens Made out of Filled Elastomers
P. Thumann, K. Swidergal, Prof. M. Wagner (OTH Regensburg)
In deep-drawing dies for steel sheet parts of car bodies huge masses are moved. To prevent vibrations, which occur by sudden acceleration or stopping of those masses, elastomeric tubular dampers [1] are used. The dampers are made out of carbon filled elastomers. A good knowledge about the material behaviour of metals is available.
Characterizing LS-DYNA Performance on SGI Systems using SGI MPInside MPI Profiling Tool
T. DeVarco, O. Schreiber, A. Altman, S. Shaw (Silicon Graphics)
SGI delivers a unified compute, storage and remote visualization solution to manufacturing customers reducing overall system management requirements and costs. LS-DYNA integrates several solvers into a single code base. In this paper, the explicit solver is hereby studied for better matching with the multiple computer architectures available from SGI, namely, multi-node Distributed Memory Processor clusters and Shared Memory Processor servers, ...
Chemically Reactive Flows in Airbag Inflator Chambers
Chemically Reactive Flows in Airbag Inflator Chambers
K. Im, G. Cook Jr., Z. Zhang (LSTC)
Airbags are part of an important vehicle safety system, and the inflator is an essential part that generates a specific volume of gas to the airbag for a short duration of time. Recently, we have developed numerical models of automotive airbag inflators in conjunction with the LS-DYNA® chemistry solver. In this study, detailed and comprehensive descriptions for theoretical models are developed for a conventional pyrotechnic inflator (PI) and a ...
Classification-based Optimization and Reliability Assessment using LS-OPT
A. Basudhar, I. Gandikota, N. Stander (LSTC)
A. Svedin, C. Belestam (DYNAmore Nordic)
K. Witowski (DYNAmore)
Simulation-based design often involves the use of metamodeling techniques that provide a cheap surrogate model to replace expensive evaluations. Several types of metamodels are available in LS-OPT, e.g. Radial Basis Function Networks, Feed Forward Neural Networks, Kriging etc.
Cloud-Enabled CAE Solutions: Requirements, Basic Concepts and Usability
A. Heine (CPU 24/7)
Up-to-date, particularly commercial methods of numerical simulation are able to meet requirements of modern product development and optimisation processes. However, essential prerequisite is not only the application software but also the appropriate High Performance Computing (HPC) resources. Specific applications, like simulation of large models with a very high number of grid points, CFD-driven design optimisation with necessary innumerable ...
Cohesive Contact Modeling in Thermoforming Simulations of Metal-CRFP-Metal Sandwich Sheets
Ö. Cebeci, A. Zeiser (Inpro Innovations­gesellschaft für fortgeschrittene Produk­tionssysteme in der Fahrzeug­industrie)
M. von Scheven (University of Stuttgart)
A novel carbon fiber reinforced metal laminate based on thermoplastic polymer is investigated in the project LEIKA. For the safeguarding of the production of the parts made of this material, coupled thermo-mechanical simulations have to be carried out. Experiments show a large relative sliding, separation and re-sticking behavior between layers during the forming of the heated sheets. Hence, each layer of the laminate needs to be modeled as an ...
Collaboration for Future HPC-based Simulation Technologies
A. Walser (Automotive Simulation Center Stuttgart)
The use of Numerical Simulation and High Performance Computing (HPC) in vehicle development has already been established for years. Nowadays it is the third pillar of vehicle development along with construction and testing. Computer Aided Engineering (CAE) methods in combination with HPC technologies enable engineers to solve complex problems in a quick and cost-effective way long before hardware prototypes are available. Furthermore it opens up ...
Comparison of Crash Models for Ductile Plastics
B. Croop, M. Lobdell, H. Lobo (DatapointLabs)
There is interest in quantifying the value of different material models being used in LS-DYNA today for the modeling of plastics. In our study, we characterize two ductile, yet different materials, ABS and polypropylene, for rate-dependent tensile properties, and we use the data to develop material parameters for the material models commonly used for plastics: MAT_024 and its variants, MAT_089 and MAT_181. We then perform a falling dart impact ...
Comprehensive Correlation of Seat Track Assembly – From Forming to Assembly Test
S. Sinne, H. Klose, V. J. Dura Brisa, P. Partheymüller (Brose Fahrzeugteile)
The dimensioning of seat structure including its adjusting components is always a challenge between comfort, lightweight and strength. The main interface between seat structure and vehicle is the s eat track assembly . It enables the length adjustment and transfers a significant amount of the crash load. The increased demands to lightweight , reduction of development time and cost efficiency require a continuous improvement of simulation models ...
Cost-Effective Sizing of Your HPC Cluster for CAE Simulations
N. Henkel, S. Treiber (GNS Systems)
The use of CAE techniques as an integral part of product development has become indispensable in the automotive industry. The investigation of different problems with the help of virtual simulation is used daily by development teams. They need considerable computing power, which is provided by HPC (High Performance Computing) clusters. Typical cluster installations in the automotive industry can range from local resources with 50 to 200 cores up ...
Crashworthy Design of Composite Structures Using CAE Process Chain
M. Chatiri (Cadfem)
T. Schütz (Adam Opel)
Prof. A. Matzenmiller (University of Kassel)
The materials used in automotive industry should play key role in overcoming the current challenging demands such as increased global competition, need for vehicles with highest efficiency, reduction in costs, stringent environmental and safety requirements. This eventual usage of lighter materials mean lighter vehicles and low greenhouse gas emissions. Composites are getting more recognition and hence being used increasingly in the automotive ...
Creation and Validation of Material Cards for Aluminium Sheet Metal Materials
R. Hennig (Aleris Rolled Products Germany)
While many simulation programs contain sufficient material cards for most of the steel materials, the aluminum cards often aren’t available yet. Therefore many of the aluminum processing suppliers have to create their own cards but aren’t willing to change them with other suppliers or customers because of the necessary high effort to get them. This leads to a higher uncertainty of the ability to process aluminum sheet metal materials in the ...
Current Status of LS-PrePost and the New Features in Version 4.2
P. Ho (LSTC)
LS-PrePost is an advance pre and post-processor that is delivered free of charge with LS-DYNA. It is designed and developed specially to support LS-DYNA in pre-processing and post-processing all in one single code. The main features in the pre-processing include CAD geometry creation and manipulation. A wide range of meshing capabilities including automatic mesh generation for surfaces, hexahedron and tetrahedron elements generation for solid
Damage in Rubber-Toughened Polymers – Modeling and Experiments
M. Helbig DYNAmore)
T. Seelig (Karlsruhe Institute of Technology)
The superior ductility and toughness of rubber-toughened polymers relies on microscale deformation and damage mechanisms such as void growth, shear yielding and crazing. In the present work, a micromechanical model for the inelastic deformation behavior of rubber toughened polymers is developed which focuses on the effect of crazing, i.e. the formation of localized cohesive zones of fibrillated material.
Damping Modeling in Woven Lattice Materials
S. Szyniszewski (University of Surrey)
S. Ryan, S. Ha, Y. Zhang, T. Weihs, K. Hemker, J.K. Guest (The Johns Hopkins University Baltimore)
Woven lattice materials were modelled to develop thin sheet dampers for attenuation of vibrations in high temperature environments. 3-D weaving has enabled manufacturing of woven lattice materials from metallic fibers that are suitable for high temperature applications. Such materials offer promising dynamic characteristic such as high vibration damping that can be combined with cooling and adequate stiffness. Dynamic tests of NiCr woven samples ...
Development of a Fully-Tabulated, Anisotropic and Asymmetric Material Model for LS-DYNA (*MAT_264)
S. Haight, C.-D. Kan (George Mason University)
P. Du Bois (Consultant)
The purpose of this research is to develop a fully-tabulated, anisotropic, asymmetric and rate dependent material model for solid elements. Physical tests of several metallic materials have shown to have anisotropic (or orthotropic) characteristics. While many material models in LS-DYNA currently have anisotropic modeling options, they are typically focused on the material forming applications – not crash and impact analysis. Unlike most ...
Development of a Tool for Automatic Calibration of Material Models in LS-DYNA
A. Mardalizad ( Polytechnic University of Turin)
E. Sadeghipour, M. Lienkamp (Technical University Munich)
LS-DYNA offers a wide variation of material cards to cover different needs in diverse applications. However, choosing the most proper material model among 250 keywords can be quite deceptive. Therefore, an algorithm has been developed to suggest proper material keywords depending on users’ applications. The algorithm is also coupled with a database of material models to look for proper material cards among the existing ones
Development of an Anisotropic Material Model for the Simulation of Extruded Aluminum under Transient Dynamic Loads
A. Smith (Honda R&D Americas)
P. Du Bois (Consultant)
T. Borrvall (DYNAmore Nordic)
The movement towards lightweight mate rials in the construction of automotive bodies is leading to an increase in parts made from extruded aluminum and other materials with a large degree of anisotropic behavior. The need to model these anisotropic properties and predict the behavior of these materials is increasing rapidly. A review of the anisotropic material models available in LS - Dyna including Material types 36, 133, 135, and 243 led to ...
Developments in LS-DYNA for Metal Forming Simulations
X. Zhu, L. Zhang (LSTC)
One - step simulation with keyword *CONTROL_FORMING_ONESTEP has been widely in use in crash and safety for forming stress and strain initialization. It has also being used for initial estimating of blank size in stamping application. One problem stamping users face is the position of the blank after unfolding can be undesirable. Also, the shifted unfolded blank is not easy to align relative to the tooling position.
Digimat Material Model for Short Fiber Reinforced Plastics at Volvo Car Corporation
M. Landervik (DYNAmore Nordic)
J. Jergeus (Volvo Car)
A pilot study has been done at Volvo Cars Corporation (VCC) to explore the potential of Digimat as material model for car components made of short fiber reinforced thermoplastics. It has been a joint project between Safety and Durability departments. It thus spans several types of analyses using both LS-DYNA, Abaqus and Nastran as finite element solvers. Additionaly, nCode DesignLife is used for evaluation of fatigue.
Discrete Element Analysis of Idealized Granular Geometric Packing Subjected to Gravity
M. Faraone, J. Chung, M. Davidson (University of Florida, Bridge Software Institute)
This paper presents discrete element analysis models for studying quasi-static stress states in idealized granular materials subjected to gravity, and utilizes geometric packings and contact mechanics. The theoretical description of granular materials in assemblies of microscopic particles is a challenging task. The particle assemblies characterize in-situ initial and boundary conditions. In turn, the conditions are used in solving the equations ...
Drop Test Simulation and Verification of a Dishwasher Mechanical Structure
O. Mulkoglu, M. A. Guler (TOBB University of Economics and Technology)
H. Demirbag (Arcelik)
It is critical for dishwasher manufacturers to design the front door hinge system and the structural components of a dishwasher assembly in terms of appearance and satisfying functional requirements. Since dishwasher users and customers request receptive quality elements from front door, it is necessary for example to know how many kilograms of decorative wooden door can be assembled to the built-in front door without endangering the durability ...
Ductile Fracture Prediction with Forming Effects Mapping of Press Hardened Steels
L. Knoerr, T. Faath, S. Sikora (ThyssenKrupp Steel NA)
P. Woelke, B. Benowitz, B. Hiriyur (Weidlinger Associates)
The escalating usage of Advanced High Strength and Press Hardened Steels to enhance crashworthiness while improving fuel efficiency through light-weighting of vehicles, has become a surmountable challenge to the auto industry. Furthermore, the expanded safety assessment like the IIHS-Small Overlap crash test greatly intensify the need for an accurate and reliable fracture prediction model, that will take into account the forming effects of the ...
Dummy-Positioning for a Whiplash Load Case using LS-DYNA Implicit
A. Hirth (Daimler)
A. Gromer (DYNAmore)
T. Borrvall (DYNAmore Nordic)
Edge-to-Edge Cohesive Shell Elements in LS-DYNA
J. Karlsson (DYNAmore Nordic)
M. Fagerström (Chalmers University)
This paper presents a new cohesive element in LS-DYNA for edge-to-edge connection of quadrilateral thin shells. Cohesive elements are an important tool for simulating the propagation of cracks in materials.
Enabling Effective and Easy to Access Simulation
E. Schnepf (Fujitsu Technology Solutions)
S. Gillich (Intel)