Simulation of Impact Proof Testing of Electronic Sub-Systems

The purpose of this paper is to document the development of a new simulation tool which is being employed to simulate the deceleration vs. time pulse imposed on electronic systems during impact tests as shown in Figure 1. The simulation tool has also been employed to predict the stress, strain, fracture, and structural failure of electronic sub-systems. Cannon tests and rocket propelled sled tests are the standard test methods employed to “proof test” the successful operation of hardened electronic systems under extreme operating conditions. The proof test consists of placing the electronic sub system into a generic steel carrier and launching into concrete or soil blocks. The peak deceleration is determined by the lower stiffness material which is the concrete / soil. Previous LS-DYNA and “Hydrodynamic” code simulations of these tests required super computers, expert consultants, extensive computer run times, and relatively high cost. The new LS-DYNA concrete material model (*MAT 159) with eroding contact option, allows rapid simulation of impact penetration and by-passes the need for excessive computer run times often required for Arbitrary Lagrangian Eulerian (ALE) LS-DYNA models and equation of state (EOS) material models. This paper describes a simple, robust, and fast running, LS-DYNA application for simulating high g cannon and sled tests. This application will run on a Dell workstation employing one Intel processor and accurately predicts; deceleration, stress, strain, fracture, and overall deformation and damage of electronic systems