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10th European LS-DYNA Conference

Würzburg, 2015

Modelling of Adhesively Bonded Joints with *MAT252 and *MAT_ADD_COHESIVE for Practical Applications
F. Burbulla (Porsche AG)
A. Matzenmiller, U. Kroll (IfM, University of Kassel)
MPP Contact: Options and Recommendations
B. Wainscott (LSTC)
There are many different contact algorithms currently implemented in LS-DYNA, each having various options and parameters. I will discuss only a few of them. Much of what is covered will only apply to the MPP version of LS-DYNA. I will start with some general background information, and then give details about some of the more interesting recent options that you might find useful.
Multi-Scale Material Parameter Identi­fication using LS-DYNA and LS-OPT
N. Stander, A. Basudhar, U. Basu, I. Gandikota (LSTC)
V. Savic (General Motors Company)
X. Sun, K. Sil Choi, X. Hu (Pacific Northwest National Labora­tory)
Prof. F. Pourboghrat, T. Park, A. Mapar (Michigan State University)
S. Kumar, H. Ghassemi-Armaki (Brown University)
F. Abu-Farha (Clemson University)
Ever-tightening regulations on fuel economy and carbon emissions demand continual innovation in finding ways for reducing vehicle mass. Classical methods for computational mass reduction include sizing, shape and topology optimization. One of the few remaining options for weight reduction can be found in materials engineering and material design optimization. Apart from considering different types of materials by adding material diversity, an ...
Multidisciplinary Design Optimisation Strategies for Lightweight Vehicle Structures
A. Prem, C. Bastien, M. Dickison (Coventry University)
The future of automobiles will be driven by lightweight structures and highly efficient powertrains. The TARF-LCV EPSRC funded project (Towards Affordable, Closed-Loop Recyclable Future-Low Carbon Vehicle Structures) aims to provide a strong scientific and technological underpinning to future LCV development in areas of advanced materials, low carbon manufacturing technologies, holistic mass-optimised vehicle structure design and closed-loop ...
New Developments in LoCo – the Innovative SDM System
M. Thiele (SCALE)
DYNAmore GmbH has founded a new wholly-owned subsidiary known as SCALE GmbH. The aim behind this move is to offer software solutions and IT services for process and data management and for FE methods development in the automotive industry. In the past years, DYNAmore has created a variety of different software products under contract of AUDI. The reason for establishing SCALE GmbH is to further develop and market LoCo and other software products ...
New Technologies for Side Impact Model Set-Up
T. Fokylidis, A. Lioras (BETA CAE Systems)
During the development and design process of a vehicle, Occupant protection in side impact studies has become a standard analysis. One of the most important issues that analysts face in side impact is how the passenger’s seat and the dummy will be adjusted in the proper position for the laboratory tests. This makes the application of numerical simulations inevitable. Simultaneously, as new legal tests and regulations are continuously introduced, ...
Non-Linear Fracture Mechanics in LS-DYNA and LS-PrePost
P. Lindström (University West/DNV GL Materials Laboratory)
A. Jonsson, A. Jernberg (DYNAmore Nordic)
E. Østby (DNV GL Materials Laboratory)
In non-linear fracture mechanics, an energy based criterion is used for assessing the risk for crack growth: if the energy release rate at the crack tip exceeds what is required for creating new surfaces in the material, crack growth will occur. Under certain assumptions the energy release rate at the crack tip can be calculated by a path independent integral, the so-called J-integral.
Non-Structural Mass Modeling in Aircraft Impact Analysis using Smooth Particle Hydrodynamics
M. Kostov, M. Miloshev, Z. Nikolov, I. Klecherov (Risk Engineering)
The non-structural mass in the large commercial airliners includes fuel, cargo, passengers, luggage, seats, lockers, etc. The straightforward approach for modelling of this non-structural mass is to include it as additional mass density to the corresponding structural elements. This approach would lead to conservative results in case of impact as the non-structural mass remains attached to the aircraft for the entire duration of the calculation, ...
Nonlinear Analysis 1980 - 2020
M. Lawson (Rolls-Royce)
Numerical Analysis of Multistep Ironing of Thin-Wall Aluminium Drawpiece
L. Brodawka, M. Kociolek, M. Siedlik, R. Budzyn, A. Furman (Can-Pack)
A. Rekas, T. Latos (AGH University of Science and Technology)
This work presents results obtained from numerical analysis of ironing with use of finite element mesh. The base drawpiece, that was a starting point in the analysis, includes a full history of deformation that resulted from simulations of preceeding operations, that is drawing and redrawing. Such a complex approach allows for a complete analysis of each successively conducted process. In the case of materials of thicknesses smaller than 0.
Numerical Analysis of Relationship between Height and Geometry of Bottom of a Beverage Can and its Resistance to Increase in Internal Pressure
L. Brodawka, M. Kociolek, M. Siedlik, R. Budzyn, M. Fijalkowski (Can-Pack)
T. Latos, A. Rekas (AGH University of Science and Technology)
Dome reversal pressure test is one of crucial quality tests required of such products as beverage cans. It gives information about resistance of a bottom in conditions of increased internal pressure. The information is important both for producers of carbonated beverages and final users. The test identifies the maximum internal pressure, which does not cause reversal buckling of a dome.
Numerical Investigation of Carbon Braided Composites at the Mesoscale: Using Computer Tomography as a Validation Tool
M. Vinot, M. Holzapfel, R. Jemmali (German Aerospace Center)
So far analytical and, to a lesser extent, numerical approaches have been limited in their ability to predict the properties of braided composites because of the high complexity of the rovings’ interlacing. While many analytical theories have been developed to approach the stiffness of braided composites, only few models are able to reproduce their behaviour up to the global failure. As part of the research campus ARENA2036, which groups ...
Numerical Investigation of the Nozzle Number on the Performance of Conical Vortex Tube
M. Guen, O. Imine, A. Miloud (University of Science and Technology of Oran Algeria)
A three dimensional computational fluid dynamic is used to analyze the mechanisms of flow inside a vortex tube. The K- ω SST turbulence model was applied to predict the performance and turbulent flow behavior inside the tube. The performance is related to the nozzle number. Five different nozzles as two, three, four, five and six were tested.
Numerical Methodology for Thermal-mechanical Analysis of Fire Doors
A. Bozzolo, C. Ferrando (D’Appolonia - RINA Group)
A. Tonelli, E. Cabella (RINA Group)
The certification process of a fire door implies that the structure is subjected to a standard fire test, to evaluate its resistance to thermal load. In particular, the door must fulfil specific requirements, such as, that the gaps among the door labyrinths and frame are able to stop flame propagation and that the mean and maximum temperature on the unexposed surface does not exceed defined values. The present paper describes the numerical ...
Numerical Simulation of Impact Welding Processes with LS-DYNA
C. Pabst, P. Groche (Technical University Darmstadt)
Impact welding enables metallurgical bonding even between dissimilar metals. The bond is formed during a high speed impact between the two workpieces to be joined. In the application, the accelerating force is provided by an explosive (explosion welding, EXW) or by an electromagnetic field (electromagnetic pulse welding, EMPW). One workpiece is usually accelerated within a few millimeters up to 200m/s and above
Numerical Simulation of the Laser Scoring Line Behavior in Airbag Deployment
M. Nutini, M. Vitali (Basell Poliolefine Italia)
S. Bianco, D. Brancadoro, A. Luera, D. Marino (FCA)
M. Olivero (CRF)
The airbag door system is one of the most delicate aspects in the design phase of a car instrument panel: seamless systems are increasingly used, which combine styling criteria with good functional performances. These systems typically include a tear seam, which may be obtained through laser scoring , to pre - determine the location of the opening during airbag deployment. The desig n of the scoring line is currently validated through ...
On Automatic Crash Model Translation
E. Di Pasquale (SimTech/ Université de Valenciennes)
This paper discusses some issues relevant to automatic crash model translation (conversion), based on SimTech experience. Automatic crash model conversion is in many ways similar to automatic language translation. The first level of conversion is “literal” translation, where each entity in the source model is translated into a corresponding entity in the target model. This issue is already complicated because such a target entity may not exist ...
Optimal Forces for the Deceleration of the ES-2 Dummy
J. Fehr, J. Köhler, C. Kleinbach (University of Stuttgart)
The purpose of this project is to improve the development process of vehicle safety systems by introducing a new analytic approach. Today, the development of vehicle safety systems, especially the airbag design process, requires many iteration loops via simulations and experiments. In this process, parameters are changed, a new simulation is conducted and the injury values are evaluated. We have a different, two folded approach: First we ...
Optimization of a Lower Bumper Support regarding Pedestrian Protection Requirements using ANSA and LS-OPT
I. Wetzstein, B. Lauterbach, N. Erzgräber, L. Harzheim (Adam Opel)
A variety of pedestrian protection requirements must be considered during the vehicle development process, in order to improve the protection of vulnerable road users. The lower bumper support, which is located at the vehicle front (s. Fig. 1), is designed to generate beneficial leg kinematics from early in the impact.
Optimization of the Blank Holder Stiffness in Deep Drawing Processes by using FEA
R. Radonjic, Prof. M. Liewald, F. Han (University of Stuttgart)
When deep drawing the parts with complex geometry, changeable thickening can occur in the flange area. Extreme thickening of the part flange will cause pressure peaks at the contact surface between blank holder and part. This undesired occurrence during deep drawing will reduce process window and process robustness as well. In this paper, an approach to optimize the blank holder stiffness in deep drawing process is presented.
Optimization of Turbine Blade Fir Tree Root Geometry Utilizing LS-PrePost in Pre- and Postprocessing
J. Jankovec (Research and Testing Institute Plzen)
This paper describes geometry parameterization of turbine blade fir tree root prepared in LS-Prepost. The generated FE model utilizes LS-OPT in optimization loop. Simulation results of LS-DYNA implicit solver were used to extract required responses. Some problems arising during solving the task will be discussed in the article.
Parameter Identification for Forming Simulations of High-Strength Steels
M. Thomisch, Prof. M. Kley (University Aalen)
Im Rahmen eines Forschungsvorhabens an der Hochschule für Technik und Wirtschaft in Aalen wird das plastische Umformverhalten von hochfesten Stählen, insbesondere Federstählen, untersucht. Im Detail stehen neben der klassischen Kenngrößen wie Fließgrenze und plastischer Verformung die Ver- und Entfestigungseffekte im Vordergrund der Betrachtung. Bei wechselnder Belastung im plastischen Bereich ist speziell bei hochfesten Stählen der ...
Performance Optimizations for LS-DYNA with Mellanox HPC-X Scalable Software Toolkit
P. Lui, D. Cho, G. Shainer, S. Schultz, B. Klaff (Mellanox Technologies)
From concept to engineering, and from design to test and manufacturing, the automotive industry relies on powerful virtual development solutions. CFD and crash simulations are performed in an effort to secure quality and accelerate the development process. The modern-day engineering simulations are becoming more complex and high in accuracy in order to model closely to the real world scenario. To accomplish such design simulations virtually on a ...
Practical Failure Criterion of Spot Weld for Crash Simulation
J.-H. Lim, J. Ha, C.-Y. Oh (Posco)
This paper proposed a practical failure criterion of spot welds for combined loading condition for crash simulation. The tests were designed to obtain the failure load of a spot weld under combined loading condition. The seven types of experimental test were conducted to obtain the component of spot weld failure criterion. The failure criterion consists of moment component including normal and shear force.
Predicting Mechanical Behaviour of Reinforced Plastic and Composite Parts
S. Calmels (e-Xstream engineering)
All the main industries worldwide are progressively adopting the usage of reinforced plastic and composite material for their product and have to face one major difficulty when it comes to design them: predicting the mechanical behavior of multi-phases and heterogeneous materials. On the structural side, each of these materials show a specific heterogeneous and anisotropic behavior in terms of stiffness, failure or electrical behavior as well as ...
Prediction of Dynamic Material Failure – Part I: Strain Rate Dependent Plastic Yielding
M. Feucht (Daimler)
R. Böhm (Karls­ruher Institut für Technologie)
P. Du Bois (Consultant)
F. Andrade, A. Haufe (DYNAmore)
The dynamic behavior of materials plays a major role in crashworthiness. During a high speed crash event, the material undergoes different strain rates that may affect its constitutive behavior. For instance, in the first milliseconds of such an event, the strain rates near the contact region between the impacting and the impacted areas are extremely high. The strain rate then tends to rapidly decrease as energy is progressively dissipated ...
Prediction of Dynamic Material Failure – Part II: Application with GISSMO in LS-DYNA
F. Andrade, A. Haufe (DYNAmore)
M. Feucht (Daimler)
R. Böhm (Karls­ruher Institut für Technologie)
P. Du Bois (Consultant)
As alluded in the first part of the present contribution, strain rate effects are quite relevant during a high speed crash event. If one intends to accurately predict failure under such conditions, it is important to properly understand and depict the underlying phenomena involved in such a scenario. For instance, the adiabatic heating that takes place during the plastic deformation process at high strain rates softens the material in such ...
Probabilistic Analysis of Process Chain “Forming to Crash“ Regarding Failure Prediction
B. Özarmut, H. Richter (ThyssenKrupp Steel Europe)
A. Brosius (Technical University Dresden)
Numerical analysis of forming and crash processes is usually carried out deterministically. However, the variations of the parameters describing materials and processes cause significant deviations in the prediction quality. This observation becomes more important if the failure prediction in process chains like forming to crash is considered. Usually, the material and process parameters are identified by means of an inverse or a direct ...
Recent Advances on Surrogate Modeling for Robustness Assessment of Structures with Respect to Crashworthiness Requirements
Prof. F. Duddeck, E. Wehrle (Technical University Munich)
Due to the inherent nonlinearity, crashworthiness is one of the most demanding design cases for vehicle structures. Recent developments have enabled very accurate numerical simulations and corresponding optimizations. Therefore, structural concepts are now much better adapted to the specific requirements. This has led to designs in which redundancies are reduced and highly effective car concepts have been derived.
Recent Developments for Thermo-Mechanically Coupled Simulations in LS-DYNA with Focus on Welding Processes
T. Klöppel (DYNAmore)
T. Loose (Ingenieurbüro Tobias Loose)
With increased mechanical and functional requirements put on many parts produced by the manufacturing industry, the numerical simulation of the process has gained importance within the last years. The main objective when applying numerical tools is an accurate prediction of the finished geometry. In order to allow for an efficient optimization procedure in the design phase of the process the complete manufacturing process chain has to be ...
Recent Developments in LS-DYNA – Part I
J.O. Hallquist, B. Wainscott and other developers (LSTC)
Recent Developments in the Electromagnetic Module: A New 2D Axi-Symmetric EM Solver
P. L‘Eplattenier, I. Çaldichoury (LSTC)
An electromagnetism module has being developed in LS-DYNA for coupled mechanical/thermal/electromagnetic simulations. More recently, a new 2D axi-symmetric version of this solver was introduced, allowing much faster simulations. In this solver, the EM equations are solved in a 2D plane, and the 2D EM fields, Lorentz force and Joule heating are then expanded to 3D elements by rotations around the axis. This allows to couple the 2D EM with 3D ...
Recent Enhancements on Short-Fiber Reinforced Plastics Modeling in LS-DYNA
C. Liebold, A. Erhart (DYNAmore)
A two-scale constitutive model for short-fiber reinforced plastics is currently being realized in LS-DYNA associated with an appropriate data-mapper (DYNAmap). For reliable structural analysis of heterogeneous materials like SFRP, the anisotropic and locally varying effective elastic properties are determined through a homogenization process of the microstructure and provided for the structural analysis.
Recent Updates in LS-DYNA Frequency Domain Solvers
Y. Huang, Z. Cui (LSTC)
Robustness Analysis of a Vehicle Front Structure Using Statistical Approach
M. Okamura (JSOL)
In this study, a process for assessing the robustness of designs has been presented, and the results are discussed using front structures of a vehicle FE model as an example. Statistical approaches have been introduced in order to assess the robustness of the structural design. Dozens of numerical simulations have been conducted taking into account uncertainties in input parameters such as spotweld failure criteria. The scatters in input ...
RollerPaG – a Tool for the Automatic Path Generation for Roller Hemming Simulation using LS-DYNA
B. Boll (DYNAmore)
O. Ghouati (Ford Research & Advanced Engineering)
Compared to tool or table-top hemming, the roller hemming is unique by its specific kinematic. A robot guides a roller along the flange to perform the hemming, with more than one robot used for an assembly in order to speed up the process. Main advantages of the roller hemming are low investment for a new product and short lead time to design and manufacture product specific equipment. Application of roller hemming was up to now restricted to ...
Scaling LS-DYNA on Rescale – HPC Cloud Simulation Platform
J. Poort, I. Graedel (Rescale)
Engineering and science simulations demand an increasing amount of computing resources. The majority of those resources consist of high performance computing (HPC) hardware, which are adaptable and highly efficient for running simulation software. Enterprises strive to create a lean and agile IT structure that both meets the current and unanticipated future needs of the various internal teams — without creating a cost structure that is ...
Shock Response Analysis of Blast Hardened Bulkhead in Naval Ship under Internal Blast
S.-G. Lee, H.-S. Lee, J.-S. Lee (Korea Maritime & Ocean University)
Y. Y. Kim, G. G. Choi (Korea Advanced Institute of Science and Technology)
It is necessary to restrict the damage area for the enhancement of ship survivability under the internal blast of a Semi-Armor Piecing (SAP) warhead inside a ship’s compartment, and to develop design guidance and performance verification technique of Blast Hardened Bulkhead (BHB) for the protection of its damage diffusion to adjoining compartment and continuous flooding.
Short and Long Fiber Reinforced Thermoplastics Material Models in LS-DYNA
S. Hartmann, T. Erhart, A. Haufe (DYNAmore)
P. Reithofer, B. Jilka (4a engineering)
In the last years the demand on weight reduction in the automotive industry has led to a strong interest for various composite applications. Due to the complexity of those usually highly anisotropic materials virtual product development is one of the key factors to understand the load carrying behavior of such parts. Furthermore enhanced CAE tools and models are necessary to ensure an efficient and robust product development.
Simplified Integrative Simulation of Short Fibre Reinforced Polymers under Varying Thermal Conditions
C. Witzgall, Prof. S. Wartzack (University of Erlangen-Nürnberg)
The use of injection moulded, short fibre reinforced structural parts in vehicle design is increasing due to their low density and outstanding mechanical properties. As the distribution and orientation of fibres within the components are heavily dependent on the moulding process, product devel-opers do well to take process simulations into consideration before performing anisotropic struc-tural analyses. To enable the use of these integrative ...
Simulating the Induction Spot Welding of Hybrid Material Joints
M. Didi, D. Wind, M. Duhovic, J. Hausmann (Technical University Kaiserslautern)
Spot welding is a very common process used to join sheet metal components in the automotive industry mass production environment. Recently, thermoplastic composites as light weight alternatives to metals have begun to make their way into production. The induction spot welding of hybrid materials, in particular aluminum or steel to thermoplastic based composite materials, is one promising method to create the required connections between these ...
Simulation Aspects for the Application of High Strength Steel Materials in Forming Processes
L. Keßler, T. Beier, H. Richter (ThyssenKrupp Steel Europe)
High-strength, cold-formable steels offer great potential for meeting cost and safety requirements in the auto industry. In view of strengths of up to 1200 MPa now attainable, some aspects need to be analyzed and evaluated in advance when designing with these materials. In addition to early assessment of crash properties, it is also highly important to design the forming process to match the material potential. To address the material potential ...
Simulation of Bird Strike on Airplane Wings by Using SPH Methodology
M. Guler (TOBB University of Economics and Technology)
T. Kiper Elibol (Turkish Aerospace)
I. Uslan (Gazi University)
M. Buyuk (Turkish Standards Institution)
According to the FAA report, 142603 bird strikes were reported for a period of 24 years, between 1990 – 2013. Bird strike with aerospace structures not only threaten the flight security but also cause financial loss and puts life in danger. The statistics show that most of the bird strikes are happening with the nose and the leading edge of the wings. Also, a substantial amount of bird strikes are absorbed by the jet engines and causes damage on ...
Simulation of Circular Sawing Proccesses
H. Vazquez Martinez (Fraunhofer IPA)
Spanende Prozesse sind durch sehr hohe Dynamik und Verformungszuständen gekennzeichnet. Mit Hilfe der Simulationstechnologie sind bereits verschiedene Zerspanungsprozesse mit guten Ergebnissen analysiert worden. Obwohl sich Kreissägeprozesse durch sehr hohe Zerspanungsleistungen auszeichnen, wurden bisher kaum Simulationen auf diesem Gebiet durchgeführt. In der folgenden Arbeit werden Simulationen von Kreissägeprozessen mit LS-Dyna durchgeführt, ...
Simulation of Forming of Paperboard Packaging using LS-DYNA
M. Schill, J. Karlsson (DYNAmore Nordic)
J. Tryding (Tetra Pak)
Paperboard is widely used as a package material for food and beverage. The ability to simulate the forming of the packages is of great interest, due to the variety in shapes and paperboard material structure combined with production speed. T
Simulation of the Electromagnetic Flux Compression using LS-DYNA Multi-Physics Capability
K. Takekoshi (Terrabyte)
The Electro-Magnetic Flux Compression system can generate ultra-high magnetic flux over 700 T with an electromagnetically imploded coil and is employedto study electronic physical properties of condensed matterssuch as carbon nano-tubes.Predicting the generation of electro-magnetic flux using computer simulation techniquesrequires electro-magnetic –thermal –structural coupling analysis. Since the electromagnetism (EM) module has been introduced ...
Simulation of the Manufacturing Process of Self-Piercing Rivets with LS-DYNA with Focus on Failure Pediction for Sheets and Rivet
M. Buckley (Jaguar Land Rover)
H. Gese, M. Reissner, G. Oberhofer (Matfem Partnerschaft)
There are many two-sheet and three-sheet material combinations in a body-in-white which can be joined via self-piercing rivets (SPR). A physical trial-and-error approach to ensure the feasibility of all combinations would be very time consuming and expensive. In addition the physical manufacturing test will not deliver the amount of accumulated damage in the sheets which is relevant for the strength of the SPR in a successive crashworthiness ...
SimWeld and DynaWeld Software tools to setup simulation models for the analysis of welded structures with LS-DYNA
Tobias Loose (Ingenieurbüro Tobias Loose)
Oleg Mokrov (ISF Aachen)
The analysis of residual stresses or distortion of welded structures requires a welding structure analysis. This kind of analysis incorporates some specifics compared to other FEM-simulations. Apart from the definition of geometry (mesh) and clamps, the welding structure analysis requires the definition of heat sources, trajectories and time schedules. The heat source applies the heat in the model according to the welding process. An equivalent ...
Small-overlap Crash Simulation Challenges and Solutions
S. R. M. Arepalli, G. Kini, A. Gittens (ESI Group)
Smart Manufacturing: CAE as a Service, in the Cloud
W. Gentzsch (The UberCloud)
The benefits for small and medium size businesses (SMBs) and research departments of using High Performance Technical Computing (HPTC) within their design and development processes can be huge. For example enormous cost savings; reducing product failure during design, development, and production; develop optimized processes; achieve higher quality products; and shorten the time to market or scientific result. Potentially, all this can lead to ...