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4th European LS-DYNA Conference

The Development of the new XJ Jaguar in Advanced Aluminium; Opportunities and Challenges
Zeguer, T. - Jaguar Cars
Comparative Performance of InfiniBand Architecture and Gigabit Ethernet Interconnects on Intel® Itanium® 2 Microarchitecture-based Clusters
Dr. Lars E. Jonsson, Dr. William R. Magro - Intel Americas, Inc.
The Intel® Itanium® 2 microarchitecture is based on a 64-bit processor architecture that is ideally suited to compute-intensive applications such as LS-DYNA. In fact, Hewlett Packard* has demonstrated outstanding performance of their Itanium 2-based systems on a range of technical computing applications, including LS-DYNA[1]. Given the success of the platform in achieving performance on a per-processor basis, we turned our attention to the ...
Automating LS-DYNA Simulation Processes using SOFY’s Rapid Application Development Environment RADE.
Dirk Ulrich - SOFY GmbH, Germany
Since the first applications of Finite Element Analysis (FEA) in automotive design this technology has gone a long way to become a standard tool fully integrated in the design process of automotive industry. Strongly promoted by progress in mathematics, information and computer technology simulation results have today reached a level of accuracy comparable to physical testing. In parallel developments in software technology – ranging from CAD to ...
FTSS FEA Dummy Models update: SID-IIs Small Side Impact Dummy Model and others
Fuchun Zhu, York Huang - First Technology Safety Systems, Inc.
SID-IIs, the small side impact dummy, is the smallest side impact crash test dummy currently available in the market, representing the anthropometry of a small female or a thirteen-year-old child. It is designed specifically to evaluate the performance of advanced occupant protection systems, such as side air bags, in automotive side impact situations. This paper presents the development and validation of new FTSS SID-IIs dummy model for LS-Dyna ...
Recent advances in THUMS : development of individual internal organs, brain, small female, and pedestrian model
Masami Iwamoto, Kiyoshi Omori, Hideyuki Kimpara, Yuko Nakahira, Atsutaka Tamura, Isao Watanabe, Kazuo Miki - Toyota Central R&D Labs., Inc.,
Junji Hasegawa - Toyota Motor Corporation
Fuminori Oshita - The Japan Research Institute, Ltd.
A finite element model of total human model for safety, which is called THUMS, has been developed in order to study human body responses for impact loads. In previous report, a mid-size adult male occupant model of THUMS was developed and validated for several impact loads. This paper briefly describes recent advances in THUMS. Individual internal organ models and a detailed brain model have been developed to be integrated with the occupant ...
Modern Field Code Cluster of Fluid Dynamics and Structure Mechanics with MetaComputing Grids for Safety and Environment Research Studies
W. Rehm, B.Wang - Forschungszentrum Jülich
B. Binninger - University Aachen
C. Nae - University Bucharest
In this this paper, we describe main results obtained within the scope of joint project activities concerning the numerical simulation of reacting flows in complex geometries. The aim is the refinement of numerical methods for applied computational fluid dynamics (CFD) using high-performance computations (HPC) to study explosion processes in more detail, especially for hydrogen safety and environment aspects of innovative technical systems. The ...
More Realistic Virtual Prototypes by means of Process Chain Optimisation
Peter Gantner, Herbert Bauer - Aalen University
David K. Harrison, Anjali K. M. De Silva - Glasgow Caledonian University
This paper is concerned with closing a gap in the process chain of metal forming. Tools for simulating the metal forming process like LS-DYNA® produce output geometries and stress information which cannot be easily re-imported in CADSystems or structure analysis programs for further processing. A concept has been developed and implemented with a corresponding program which allows the re-importation of parts with certain topologies (tube, plane) ...
A method for modifying the forming tool geometry in order to compensate for springback effects
Anders Jernberg - Engineering Research Nordic AB, Sweden
There is always a certain amount of springback deformation in a metal forming process. The high strength steel is becoming a more attractive choice for many applications when low weight of the structure is of importance. One major drawback with the high strength steel is that the springback deformation increased compared to low strength steel. All currently known techniques to reduce the springback deformation are used in tool design today, so ...
“Forming to Crash” Simulation in Full Vehicle Models
Janka Cafolla, Roger W. Hall, David P. Norman, Iain J. McGregor - Corus Automotive
Improving the accuracy of virtual prototypes helps to shorten product development times and reduces the number of physical prototypes required. One way in which the accuracy of crash analysis can be improved is to include the effects of forming in the material properties. Corus has developed a three-step “Forming to Crash” process to account for formed properties in crash analysis during both concept and detailed vehicle design stages. The first ...
Simulation of the forming process of the Metal-Plastic-Metal sheets
Dr. R. Borg - Engineering Research Nordic AB
Metal-Plastic-Metal (MPM) sheets consists of two metal sheets bonded together by a thin polymer layer. Modelling this sheet structure with a single shell element gives a too stiff response. The large shear deformation in the polymer layer can not be represented correctly. A method is presented on how to simmulate the forming process of MPM-sheets by which the two metal sheets are modelled with two layers of shell elements. The bonding polymer is ...
Finite Element Analysis of Stresses Due to Normal and Sliding Contact Conditions on an Elastic Surface
Anantha Ram B.S., Joachim Danckert, Torben Faurholdt - Aalborg University, Denmark
Wear prediction necessitates the investigation of elastic stresses developed in the workpiece material due to impact and sliding of abrasive particles in tribological contact situations. LS-Dyna implicit finite element analysis is used to investigate these contact stresses in the workpiece material under imposed Hertzian pressure loading. A line contact condition (cylindrical body on a plane surface) is assumed and the predicted stress field is ...
Sheet Metal Forming: Spring-back of hydro mechanical deep drawn parts
Jens Buchert, Herbert Bauer - University of Applied Sciences, Germany
David K. Harrison, Anjali De Silva - Glasgow Caledonian University, UK
Active hydro mechanical forming (AHMF) has been developed in order to meet the demand of the automotive industry for economical production of sheet metal parts with more individuality in small lot sizes. Conventional deep drawing of automobile parts which have large outer surface areas (such as roofs, doors and hoods) leaves them with a very small dent resistance. This is caused by the low deformation degree in the middle of the part. This low ...
Influence of the Effect of Strain Rates on Springback in Aluminum 2024 (ISO AlCu4Mg1)
Pravin Kulkarni, Shashikiran Prabhakar - Cessna Aircraft Company
Forming of aluminum sheets in T-temper is a much sought after industrial process, especially in the aircraft industry. However, the success of this process largely hinges on the ability to predict springback accurately. Aluminum sheets in T-temper exhibit approximately twenty percent variability in material properties and also the amount of springback is very large. This makes tool design for aluminum in T-temper an iterative and difficult to ...
Sheet Metal Forming in a Virtual Reality Environment using LS-DYNA and Neural Networks
Ashwini S. Gokhale - Wichita State University
Manufacturing process simulation using finite element techniques has immensely contributed to ensuring the success of concurrent design methodologies. However, Finite Element Methods (FEM) is computationally expensive and consequently unsuitable for design and manufacturing optimization in a production environment. In this research, a coupled Artificial Intelligence (AI) and FEM technique was developed to simulate and predict process response to ...
Stress Analysis of Connector Pin Produced by Reverse Stamping Process with LS-DYNA Numerical Simulation and Comparison to Experiments
Won Yong-Hee, Kim Jeong-Ho, Lee Young-Jun - LG Cable Ltd
The conventional progressive stamping process used in producing connector pin makes the pin-shift from side to side due to elastic recovery reffered to springback phenomenon. As the solution of this problem, the reverse stamping process was introduced to the production process of connector pin in LG Cable. In this study, we performed research on the feasibility of reverse stamping process to support a design guide of which process. For this ...
Newly Developed Capabilities of DYNAFORM Version 5.0
Wenliang Chen, Dingyu Chen, H.Xie, Quanqing Yan, Arthur Tang, Chin Chun Chen - Engineering Technology Associates, Inc., USA
Over the past two decades, the finite element analysis (FEA) has emerged as one of the most important engineering tools in the many industries, due to its flexibility and accuracy in prediction. Nowadays, it is widely used in sheet metal forming industry to predict the forming feasibility of wide variety of complex components, ranging from aerospace and automotive components to household products. As the demand of FEA accelerates, the need for a ...
Manufacturing Simulation of an Automotive Hood Assembly
Chris Galbraith, Dylan Thomas - Centre for Automotive Materials and Manufacturing currently with Honda R&D Americas, Inc.
Mark Finn - Alcan International Ltd.
This paper presents the results of applying the finite element method to calculating the spring back of an automotive hood assembly, and its application to the functional build method. The assembly was comprised of six individual panels: an inner panel, an outer panel, a major reinforcement, a latch reinforcement, and two hinge reinforcements. Finite element simulations were conducted for forming each of the six components. Each component was ...
Process optimised FEA- Calculation for Hydroforming Components
Michael Keigler, Herbert Bauer - University of Applied Sciences, Aalen, Germany
Richard Hall - University of Wolverhampton, UK
Prof. Musa Mihsein - De Montfort University, UK
Virtual Die Tryout of Miniature Stamping Parts
Ming-Chang Yang, Tien-Chi Tsai - Metal Industries R&D Center, Taiwan
The authors would like to present the whole procedure of using dynamic explicit finite element method to aid multi-stage miniature stamping die design. How to cost down and time saving are the key issues for tool maker in Taiwan. It has been applied to many automobile components and metalwork successfully by computer aided design and engineering analysis. In this paper, we dedicated our application of these technologies to small scale stamping ...
FINITE ELEMENT ANALYSIS OF SUPERPLASTIC FORMING PROCESS USING LS-DYNA
Haryanti Samekto - Universitaet Stuttgart
Karl Roll - DaimlerChrysler AG
Superplastic forming process has been a standard manufacturing process in aircraft industry and its applications in other industries are increasing. Superplasticity is utilised in forming parts which can not be produced technically or economically using materials with ordinary ductility. As superplastic deformation should be carried out under certain strain rate in which m value is maximal, the finite element method is applied to model the ...
LS-DYNA Applications in Shipbuilding
Hervé Le Sourne, Nicolas Couty, François Besnier - Principa Marine, France
Cyrille Kammerer, Hervé Legavre - DCN Ingénierie, France
Ship and submarine structures have long been studied thanks to finite element methods. Their large dimension and complexity, the coupling with heavy fluid and the presence of a free surface raise numerical problems on the field of dynamic analysis. This is particularly true for extreme or accidental situations such as collision and grounding, underwater explosion and severe fluid impact. This paper describes first numerical methods and tools ...
Implicit Functionality in LS-DYNA v970
Dr. B. Maker, Dr. R. Grimes, Dr. C. Ashcraft - Livermore Software Technology Corp.
How to Develop a Five Star Car by using LS-DYNA
R. Malcusson - Saab Automobile AB
 
Current and future developments of LS-DYNA I
Dr. Hallquist J. O. - Livermore Software Technology Corp.
LSTC’s Perspective on the future Version 970 status Recent developments for crash Arbitrary Lagrangian-Eulerian Developments Implicit Developments EFG (Mesh-free) Developments MPP Outlook
Current and future developments of LS-DYNA II
Dr. Hallquist J. O. - Livermore Software Technology Corp.
 
Recent New Developments in Contact Mechanics
P. Wriggers, K. Fischer - University of Hanover
A. Rieger - Continental AG
During the last years considerable effort was devoted to better numerical treatment of contact problems. This fact is due to the growing computing power which lead to more and more sophistication and detailed technical models within engineering analysis. Due to the more precise modelling within the associated discretization process often unilateral constraints have to be considered. Hence better discretization techniques, especially for finite ...
CAE Data Management and Quality Assessment of LS-DYNA Crash Models using V-CESS
Matthias Eick, Dr. Lars Fredriksson, Dr. Jochen Seybold - Altair Engineering GmbH
The meshing, modeling and evaluation of LS-DYNA crash models for vehicle crash simulations is constantly subjected to an increase in complexity, since the model sizes grow, several vehicle variants are instanced from one single CAE data set and since the number of load cases and the requirements on the evaluation quality are constantly increasing. Current models sometimes contain more than 1000 different components and 1 million elements. In ...
Virtual Reality in Crash Simulation
Friedhelm Birk - 3Dims GmbH Frankfurt, Germany
Since simulation of complex things like crashing a car becomes more precise and more affordable its only natural that one wants to analyze the results in a way a humans nature can intake complexe data best: visually.
scFEMod – The New Preprocessor for Efficient Assembly and Model Validation
Ove Sommer, Thomas Ertl - science+computing
Norbert Frisch, Dirc Rose - University of Stuttgart
This paper presents a new preprocessor for the assembly of independently meshed car body parts. The assembly process gains more and more importance in the preprocessing of crash-worthiness simulations. It is desirable to take simulation results into consideration for construction decisions already in the early phase of the car development process. At this stage, CAD data unfortunately does not contain any information about constraints like ...
A New Simulation Method for Airbags With Multiple Compartments (Adaptive Euler Domains)
R.S. Sadeghi, W.A. van der Veen - MSC.Software Corporation
The paper presents a new simulation method for airbags with multiple compartments. In recent years many accidents happened with passengers that were out of position (OOP) when their airbag deployed. Therefore new safety regulations have come into effect in the USA and an airbag now has to meet several requirements that concern out of positioning. In meeting these requirements simulations of deploying airbags are very useful and are widely used. ...
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