Bumper Crash Final

Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
. Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Tutorial - Crash Bumper Analysis

Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Why Crash Analysis?
To find deformation, stress, and energy absorbing capacity of various
structural components of a vehicle hitting a stationary or moving object.

The component is said to be crashworthy (safe) if it meets the plastic strain and
energy targets.

Bumper is one of the components which is used to protect passengers
from front and rear collision.

Bumper crash tests are necessary for instance to calculate the energy
absorption of this component during a crash.
Agenda
Geometry meshing with HyperMesh
Mesh preparations and modifications with HyperCrash
Material creation and assignment
Property creation and assignment
Welding
Mirror to full model
Global contact definition
Load case creation
Model check
Start of simulation

Agenda
Welding
Load case creation
Model check
Start of simulation
Mesh preferences for crash analysis
For crash analysis the preferred element type is hexa over tetra when
using 3D elements, shell elements are used for 2D modeling (as in
the case of this analysis). Follow the mesh flow line requirement and
avoid rotating quads, or diamond element formation.
Constant mesh size is preferred over variable mesh size.
Make sure the element quality matches requirements. Checking
element quality is a good practice.
Element characteristic lengths should allow a reasonable initial time
step.
Mesh preferences for crash analysis
We recommend to also view the
video series by Paul du Bois
(available on the Academic Blog)

http://www.altairuniversity.com/2013/03/01/some-
principles-of-explicit-finite-element-analysis-by-paul-du-
bois-and-altair-engineering-inc-videos/

Meshing
Start HyperMesh 12.0, select RADIOSS Block user profile
Select
RADIOSS
Block 110
from User
Profiles
Meshing
Open the .hm file
Open
Bumper_System_2012_A.hm
Meshing
Check and configure element type
Go to
2Delement types
Meshing
Configure element type
Select
2D&3D
Set to:
SHELL 3N &
SHELL 4N
Click
return
Meshing
2D Automesh
Go to
automesh
from the 2D
page

Meshing
Mesh geometry with 2D elements using automesh panel
Change the
entitiy selector to
surfaces, double
click and select
all, set element
size to10 mm
Meshing
Export the mesh as a RADIOSS (BLOCK) deck
Export mesh
Agenda
Welding
Load case creation
Model check
Start of simulation

Mesh modifications
Start HyperCrash 12.0 and configure.
Set Working directory
to a suitable location
Choose
RADIOSS V11
Unit system on
kN mm ms kg
Switch GUI to new and
start Hypercrash
Mesh modifications
Import of the Mesh/Model
Import of a
RADIOSS mesh
Mesh modifications
Import of the Mesh/Model
Accept the
transformation of
the unit system
Mesh modifications
Create new assemblies and sort the parts
Mark one part
<left click>

Open the
submenu with
<right click>
Choose New
Assembly to
create a new:
BUMPER_BEAM

Repeat the whole
step and name it:
CRASH_BOX_LHS

Mesh preparations and modifications

Activate part
selection with box

Select the
BUMPER_BEAM
parts with a box

- Parts will be
selected in tree
Pull the marked
parts with the
<middle mouse
button> to the
assembly
BUMPER_BEAM

Mesh modifications
- Activate simple part
selection
- Pick both
CRASH_BOX parts
- Confirm the
selection with yes

- Parts are
selected in the
tree now
Pull the Parts into
the assembly
CRASH_BOX_LH
S using the
<middle mouse
button>

Mesh modifications
Equivalence unconnected nodes
Mesh Editing
Node Modify
Select the parts of
the
BUMPER_BEAM
in the tree

Why equivalence?
To ensure connectivity between the elements, you need to equivalence any
coincident nodes in the model. The equivalence operation identifies any
location where two or more nodes exist within the specified search tolerance.
During equivalence, one of the nodes is retained and any element definitions
referencing the other nodes are re-defined to use the retained node.
Mesh modifications
Add selected parts
of Tree
- Nodes of the
BUMPER_BEAM
are highlighted

Activate Set 1
Mesh modifications
Activate Set 2

Add selected parts
of Tree
Nodes of the
BUMPER_BEAM
are highlighted
again

Gap search: 1mm

Mesh modifications
Click on See
node(s) to merge
Now you can see,
which nodes
(highlighted in red)
will be equivalenced
(arrows show the
direction of merging)

Conclude by
clicking Save.
Changes will be
saved in model
and NOT on disk
(HyperCrash does
not have its own
file format)


Switch to Tree
and choose the
first part of
CRASH_BOX_LH
S
To isolate the
selected part(s),
click Isolate Tree
Selection

Mesh modifications
You can change the
view with Display
mode, switch here
to Shaded with
Lines

The perspective
can be switched on
or off by pressing
the key P

Zoom to bad-
connected flanges
(using scroll-wheel)

Mesh modifications
Measure the
distance between
these two nodes
(longest distance)

The results appear in
the Message area

Click cancel to close
it

Mesh modifications
Connect each set of
nodes (you have to
confirm with enter
every time)

Go to Mesh Editing
Node Modify
To finish this step,
press Close

Mesh modifications
Go to Mesh
EditingMove
and select the
suitable nodes
Problem: deformed
mesh

Finish the selection
with Yes

Mesh modifications
Movement plane
Left click on the red
node and pull till you
find a visually
improved mesh

Finish with Yes

Mesh is now
perpendicular

Mesh modifications
Switch to Tree and
choose the second
part of
CRASH_BOX_LH
S

To isolate this
part, click
Isolate Tree
Selection

Mesh modifications
Measure
maximum
distance (in this
case: 1.9999)
Finish Measuring
by clicking
Cancel
Merging occurs
automatically


Go to Merge multi
Then click on Set
1, and click on
add selected part
of Tree, repeat the
same for set 2
input gap search
2mm and click
See to visualize
confirm with save
and Close
afterwards

Mesh modifications
Global depenetration
Show all using
Display All (or
CTRL+S) and
zoom in with Fit
Model (or
CTRL+R)
Menu LoadCase
Contact Interface

What are penetrations and intersections?
Penetration is defined as the overlap of the material thickness of shell
elements, while Intersection is defined as elements that actually pass
completely through one another
All models and especially impact models should be checked for
penetrations and intersections and depenetrated to ensure the
integrity of the model
Penetrations adversely affects results and should be removed

Mesh modifications
Create a new
object Multi
usage (Type 7)
Mesh modifications
Activate Self
Impact checkbox
for autocontact

Add selected
parts by box
Mesh modifications
Input 1 at Min. gap
for impact
activ.(check next
slide for Gap input
options).
Save and Close

Intersection-penetration check
HyperCrash checks for intersections and penetrations. The list of
intersecting nodes is displayed at the bottom of the menu.
To find and to correct the penetrations use the variable gap or a
constant gap option.
1.The variable gap option (if "Gap_interface" = "variable")
searches and corrects the penetrations taking into account the
actual thickness' of the plates (coming from the PID).
2.The constant gap option (if a value for "Gap_interface" is
entered) uses a (user-defined) fixed value to search and correct
the penetrations (the value can be the gap of the interface, for
instance).
Mesh modifications
Menu: Quality
Check All Solver
Contact Interfaces
VERY IMPORTANT
and USEFUL
FUNCTION !!!
Use it as often as
you modify
mesh/model

Mesh modifications
Searching for
Intersections and
Penetrations (if some
found, the number
will be displayed).

After selecting
intersection from list,
it will be shown
highlighted in a
transparent model
Zoom to it as near
as necessary

Isolate Crashbox
1. Correct
INTERSECTIONS
(because its more
difficult)

Mesh modifications
- With Move nodes
1 by 1 move the
intersection node
away
- Afterwards confirm
two times with Yes
and Close.

Mesh modifications
Global depenetration (it is strongly recommended to remove the intersections before
removing the penetrations)
Recheck for
Intersections and
Penetrations
(Quality Check All
Solver Contact
Interfaces)
- There shouldnt be
any intersections,
now.

Assign all
penetrations and
display all

2.Correct
Penetrations
(very easy)
Mesh modifications
Select the parts
which are not
allowed to be
modified (Fixed
parts).

Depenetrate auto

Mesh modifications
LoadCase
Contact Interface

Mesh modifications
Global depenetration: delete temporary contact interface
Select Contact and
Delete selected
item(s)
Close
Agenda
Welding
Load case creation
Model check
Start of simulation

Crashbox Material (Steel) generic DP600
Model Material
Pick this Crashbox
Parts from the
Tree
Creates a new
object Elasto-
plastic
Johnson_Cook
(LAW 2)
Why Johnson_Cook (LAW 2)?
This is an elasto-plastic material which includes strain rates and
temperature effects (stress vs plastic strain law)
The yield stress is converted into true stress
In this law the material behaves as linear elastic when the equivalent
stress is lower than the yield stress. For higher stress values the
material behavior is plastic.
Note: find a summary on true
stress strain vs. enginering
stress strain in the Student
Guide (Chapter 13.4)

Include picked
parts and select
both parts of the
Crash Box
Yes to confirm


Click Save


Bumper Beam Material (Steel) generic DP1000
Creates a new
object Elasto-
plastic
Johnson_Cook
(LAW 2)

Go to Tree
Choose all parts of
the
BUMPER_BEAM
and turn back to
Material

Add selected parts
of Tree

Add simple Failure
criteria
(deletion at
equivalent plastic
strain of 30%)
Finish this with
Save

Agenda
Welding
Load case creation
Model check
Start of simulation


Crashbox Shell element definition (thickness = 2.2 mm ) and assignment
Select Crash Box
parts out of the tree

Model Property
Creates a new
object Surface
Shell (1)

Add Selected Parts
of Tree

Save to finish input

Best choice
for crash

Bumper Shell element definition (thickness = 1.8 mm ) and assignment
Creates a new
object Surface
Shell (1)

Use Include picked
parts to select the
front and horizontal
parts in the middle of
the Bumper_Beam
(not the rear Bumper
Beam sheet)
Confirm with Yes


End with Save
Why QEPH shell formulation?
QEPH (Quadrilateral ElastoPlastic Physical Hourglass Control) element
With one-point integration formulation, if the non-constant part follows exactly
the state of constant part for the case of elasto-plastic calculation, the
plasticity will be under-estimated due to the fact that the constant equivalent
stress is often the smallest one in the element and element will be stiffer.
Therefore, QEPH, defining a yield criterion for the non-constant part seems to
be a good ideal to overcome this drawback.
QEPH shells are more accurate for elastic or elasto-plastic loads, whatever
the loading type - quasi-static or dynamic.
QEPH shells will give better results if the mesh is fine enough. It is not
recommended for coarse mesh.

Creates a new
object Surface
Shell (1)

With Include
picked parts
select
Bumper_Beam
Rear part
Finish with
Yes

End with Save

Why use 5 integration points in the thickness
of shell elements?
In case of an elastic behavior, one gets the exact solution from three
integration points that is to say that the bending moments are exactly
integrated through the thickness of the shell and it is not necessary to use
more integration points.
In case of a plastic behavior, the bending moments are not integrated
exactly. Using more integration points, the solution becomes more accurate;
so it is recommended to use five integration points.


Shell element definition and assignment
Plausibility check:
Are all properties
created and
assigned ?

End property menu
with Close
Agenda
Welding (SPOTWELDS)
Load case creation
Model check
Start of simulation

SPOTWELDS

Connection of Crash-Box upper with Bumper-beam
Rotate the model
to see its rear
parts
Choose
Connections
Spotweld Create
SPOTWELDS

Connection of Crash-Box upper with Bumperbeam
Include picked parts
Select both parts
(bumper rear and
crash box upper).
Selected parts
are highlighted in
red

Confirm selection
with Yes
SPOTWELDS

Pick a point and
see spotweld and
click on marked
elements to give the
Spotwelds the right
position
Every Spotweld has
to be confirmed with
Enter
Save to save the
spotwelds in the
model
Cancel
Now repeat the same steps with the lower part of the Crash Box)
SPOTWELDS

Choose Include
picked parts
Pick both
Crash-Box parts
(crash-box
upper and crash
box lower)
Validate with Yes
SPOTWELDS

Line and type in 30
for the Pitch length
(distance between
spotwelds)
Click at Beginning-
Point and End-Point
for SPOTWELD line
Confirm with Save.
Follow the same
procedure at the
other side

SPOTWELDS

Spotwelds are mesh
independent. These
are modeled using
spirng elements with
both sides of the
spring linked with
mesh using tied
interface.
Agenda
Welding (SPOTWELDS)
Load case creation
Model check
Start of simulation

Mirror preperation
Save your model (File Export RADIOSS)
Open the saved location and delete the *.M00 file

Import the ..000.rad file back in HyperCrash to mirror.

In order to mirror elements and spotwelds, follow the below:

Duplicate all parts with all options
Select: Mesh Editing
Part Duplicate
Mark the highest
model hirarchy

Duplicate all parts with all options
Mirror
Include selected
parts of Tree
Apply Mirror
Save and Close
Mesh + all options

Equivalence at mid/mirror plane
Attention:
Nodes at the
midplane ar NOT
equivalenced
already!
New assembly:
Duplicated Parts
was created

Mesh Editing
Node Modify
Select the new
(duplicated)
BUMPER BEAM
from the tree

Add selected parts
of Tree
Merge multi
Nodes of the new
(duplicated)
bumper are
highlighted
Switch back to the
tree selection


Switch back to
Mesh Editing
Select the old
BUMPER BEAM

Add selected parts
of Tree (Nodes of
the original
BUMPER BEAMS
are highlighted)
Select Set 2
Type 1 in gap
search to merge

Click See node(s)
to merge
and rotate graphics
area to verify the
nodes to merge
Click Save to
confirm
Close

Connections
Spotweld Extract
from Model

Connections
Spotweld Modify

Use
Select/Unselect all
spotweld(s) to
select all spotwelds
of the list

Display all
spotwelds using the
tool See selected
spotweld(s)
All O.k.?
Then go for
close

Agenda
Welding (SPOTWELDS)
Load case creation
Model check
Start of simulation

Global Contact Definition

Interface properties for penalty contact definition
Choose highest
level in Tree to
select all (shell
meshed) parts
LoadCase
Contact
Interfaces
Create/Modify

Creates a new
object Multi
usage (Type 7)
Why type 7? What is interface gap?
This interface simulates the most general type of contacts and impacts
Impacts occur between a master surface and a set of slave nodes.
All limitations encountered with interface types 3, 4 and 5 are solved with this
interface.
It is a fast search algorithm without limitations.
Interfaces have a gap that determines when contact between two segments
occurs. This gap is user defined, but some interfaces will calculate an
automatic default gap.


Activate
Self-Impact
Add selected parts
of Tree (all shell
parts should be
selected

End with Save
and Close
What is coulomb`s friction law?
Type 7 interface allows sliding between contact surfaces. Coulomb friction
between the surfaces is modelled.
Coulombs friction law is a classic friction law which states that frictional force
= coeff of friction*force acting on the object [F
f
= *F]. Example - a block
sliding on an inclined plane.
It states that the Kinetic friction is independent of the sliding velocity.
The Coulomb approximation mathematically follows from the assumptions
that surfaces are in atomically close contact only over a small fraction of their
overall area, that this contact area is proportional to the normal force
(until saturation, which takes place when all area is in atomic contact), and
that frictional force is proportional to the applied normal force, independently
of the contact area .

Agenda
Welding (SPOTWELDS)
Load case creation
Model check
Start of simulation

Load case creation

Create rigid body
Switch to XY View
Press the P key
to turn off the
perspective!
What is a rigid body?
A rigid body is an idealization of a solid body in which deformation is
neglected. In other words, the distance between any two given points of a
rigid body remains constant in time regardless of the external forces exerted
on it.
Rigid body elements are used to
- impose equal displacement to a set of nodes;
- model rigid connections and pin-joints;
- enforce symmetry;
- model transitions, connections, spot-welds, seam-welds between non-
matching (dissimilar) meshes;
- distribute concentrated loads/masses to a set of nodes

Load case creation

Create Rigid body
Mesh Editing
Rigid Body
Create

Load case creation

Create Rigid body
Name RigidBody
and Ok

Add nodes by box
selection and pull
a box over the last
row of crashbox
nodes
Load case creation

Define vehicle mass component to partially take into account the inertia
properties and mass of the missing parts of the vehicle
Adjust
Properties of
rigid body:
Save and
Close
Load case creation
Define vehicle mass component to partially take into account the inertia
properties and mass of the missing parts of the vehicle
Display Graphic
Objects On/Off
Rigid Bodies.

To simplify the
model, several of
the components are
not modelled to
save time and cost.
Instead they were
represented as a
point mass and rigid
bodies.

Load case creation

Rigid body Boundary Condition definition
LoadCase
Boundary
Conditions
Create

What is a boundary condition?
A boundary condition is simply the load applied to the system.
Boundary conditions are an approximation of the actual physical conditions
the system experiences and should match reality as closely as possible.
Boundary conditions include forces, imposed velocities and accelerations,
pressure loads, constraints on the movement of certain nodes, etc.

Load case creation

Rigid body Boundary Condition definition
Name this
boundary condition
Ok

Add/Remove nodes
by picking and
select the Master
Node of the
RigidBody

Select all degrees
of freedom except
the translation to
x(Tx)
Save
Why Translation to TX not chosen?
In this case the boundary condition being created is to constraint he
movement of the component in unwanted directions.
We do not constrain movement in the TX direction or Translation in the X
direction, because we need the bumper to move in this direction for our
simulation, this also reflects the reality of its movement.
Load case creation

Boundary Condition definition
Display Graphic
Objects
On/Off Boundary
Conditions.

Load case creation

Gravity Load
LoadCase
Gravity Load
Load case creation

Gravity Load
Give name and
Ok
Record data:

t = 0
9.81e-3

t = 100
9.81e-3

Save
Define time function
Load case creation

Gravity Load
Choose Add all
nodes
Pick Z as
direction
-1 for the negative
Z-direction

Save and Close

Load case creation

Gravity Load
Display Graphic
Objects On/Off
Gravity
Load case creation

Initial velocity definition
LoadCase Initial
Velocities
Load case creation

Name and Ok
Add all nodes
-5 (m/s) in X-
direction

Save and Close

Load case creation

Display Graphic
Objects
On/Off Initial
velocities
Load case creation

Rigid Wall definition
LoadCase
Rigid Wall
Create
What is a rigid wall?
A rigid wall is a nodal constraint applied to a set of slave nodes in order to
avoid the node penetration to the wall. If contact is detected, then the slave
node acceleration and velocity are modified.
Mainly to constrain movement of a moving body after impact, We will be using
a cylindrical wall.
An infinite cylindrical wall is a cylinder which extends to infinity. It is defined
with two points (or one point and one node) and a diameter. Note that contact
is only possible from outside the cylindrical wall.

Load case creation

Rigid Wall definition
Select Rigid wall
type Cylinder
Take over the
properties
See, Save and
Close
Load case creation

Definition of Accelerometer for post processing
Data History
Accelerometer
Create

The accelerometer
option computes a
filtered acceleration
in the output system
Load case creation

Name Ok
Select with Pick
nodes to add one
node to be defined
as accelerometer
Cut off frequency of
1.650 (=1650 Hz)
equates:
CFC1000 filtering

Save and Close

Load case creation

Data History
Section Create
Load case creation

Type Name Ok
Select both
Crashbox parts
using Include
picked Parts
Conclude with Yes

Load case creation

Define section
plane with 3
nodes
Adjust with shells
and nodes
correct the
section plane
Load case creation

Type the name
Ok
Before: Afterwards:
Save
Agenda
Welding (SPOTWELDS)
Load case creation
Model check
Start of simulation

Model Check

Clean model
Mesh Editing
Clean
Model Check

Clean model
Clean and Close
Review the
checkboxes
Model Check

Interface Checker
Quality Check All
Solver Contact
Interfaces
Model Check

Interface Checker
Results should
look like:
0 Intersections
and
0 Penetrations
Penetrations (not
Intersections) can
be dissolved
automatically by:
Depenetrate auto

Close

Model Check

Model Checker
MOST important
Function (ALWAYS
to use before the
export of the
model):

The Model
Checker
Model Check

Model Checker
Most Warnings can
be ignored or be
resolved
automatically.
(Beware of Errors
Must be solved)
Close

Agenda
Welding (SPOTWELDS)
Load case creation
Model check
Start of simulation

Simulation
RADIOSS (BLOCK) is the solver used for solving non-linear implicit and
explicit problems.
HyperCrash/RADIOSS essentially writes out starter file and Engine file.
Engine files are used to set up the model, including termination times, output
requests, and other checks that control the execution of the job.
Starter file contains actual model definition. Engine file executes the actual
computation.
Simulation parameters

Control Card
Model Control
Card
Simulation Parameters

Control Card
take required
settings
Make sure to save every setting before
you move to the next Control Card

Defines the time for running

Writes animation files at a time frequency
of 5 and the start time is 0

Writes a time history file. the time at which
the time history file begins.

Generates animation file which contains
element data for specified results (Energy
desity, hourglass energy, etc)

Writes nodal scalar data (mass, inertia,etc)

Writes vector data (velocity, acceleration, etc..
Export model

Export Model
Select File
Export
RADIOSS
Export model

Export Model
Choose path
Give file
name

Export model

Create/export starter file with model (_0000.rad)
Possibility to write
comments and/or
model evolution
into model file
(Start with # at
beginning of every
row for comment)

Save Model

Start RADIOSS

Start model
START
Programme
Altair
RADIOSS
Start RADIOSS
Start model
Select working
directory

Choose:
RADIOSS
Version
(Starter and/or
Engine)
Number of
CPUs

Run
Start RADIOSS

Start model
RADIOSS Starter
announces:
0 ERROR(S)
0 WARNING(S)

RADIOSS Engine
starts the
simulation and
writes Animation
files
Post processing

Model post processing with HyperView
Open animation
files (also during
simulation
possible)
With Load Model

Play animation

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