A design of experiments approach to conducting

sensitivity analyses in finite element modelling for thin

walled tube loaded axially in LS DYNA

By - Nitin Kharade
Under guidance of
Mr Atul Patil

Start Date - 11 Dec 2017

First Review - 24 Dec 2017
Second Review -
End Date -
 Content
• Introduction
• Hand Calculation
• Experimental result
• Procedure for creating deck
• Parameter for study
• Flow chart for parameter
• DOE (Partial fraction method)
• Numerical result obtained and validation with experimental result
• Result and Discussion
• Future scope
 Introduction
Nowadays, finite element analysis (FEA) is widely used in
crashworthiness analysis since it has many advantages.
Compared to the conventional method such as experimental and
closed-form theoretical analysis.
Aim of the study is to investigate the effect of various parameters on
thin walled tube loaded axially.
Hand calculation for thin walled tube

17.9753 19.543

20.0956 21.8484

22.9311 24.9312

28.9720 31.4990

26.1094 28.3867
Hand calculation for thin walled tube

28.9524 31.4777

19.1318 20.8005

31.7797 34.5516
 Hand calculation for thin walled tube
• Full plastic bending moment, is derived from equation

where and t refer to the flow stress and thickness of tubes

respectively.
Different researchers have usedvarious different measures for the flow
stress
 Experimental result obtained
Model name – SAASC 13
Deformation profile = A(7) bottom D(13), N = 3.
d(Final reduction of axial length) = 326 mm
Pp (peak crushing force)= 49.9 KN
Pm (mean crushing force force) =24.41 KN
Energy Absorbed = 7.96 KJ
Specific energy absorption =
Load Vs Displacement curve for crush
tube
Quasi statically loaded crush tube profile
 LS-DYNA deck preparation
• Geometry creation
• Meshing
• Material
• Properties
• Contact
• Constraint
• Control cards
 Geometry & mesh model considered
for study
• Geometry • Mesh model

Type of 4 node shell

Outer Diameter 50.8 mm element element
Height 430 mm Size of 3 mm
element
Thickness 1.53 mm Element 16
formulation

Fig : Schematic representation of model Fig : Mesh model of thin walled tube (Preprocessor - Hypermesh)
 Material properties of Aluminium
Alloy 6063 T6
Parameter(Units) Value for Aluminium alloy 6063-T6
Density(g/cm3) 2.7
sy (Mpa) 225
su(Mpa) 268
er, %+ 8.9
Eh(Mpa) 300
E(Gpa) 69
Poissions ratio 0.33

In LSDYNA MAT 24 Elastic Plastic card is used for above material.

Cowper-Symonds coefficients for above material is
D (s–1) = 9.390e10
Q = 9.55
Engineering Stress Vs Strain behavior for
material
 Material modelling in LS DYNA
• Aluminium allot 6063 T6 is model with elastic plastic MAT 24 card
(Piecewise linear Plasticity)
 Properties assign to crush tube
• For First simulation ELOF 16 is with shear stress correction factor for
shell element is 0.8333
• Number through thickness integration point is 5
 Contact Assign

Base plate and crush tube assign with Automatic

Surface to surface contact

Crush tube assign with

Automatic surface
To surface contact .

Impacting plate and crush

tube assign with Automatic
surface to surface contact.
 Constraint
• Base plate is constrained in all DOF by CMO option in rigid material

Impacting plate allow translation in Y direction only all other DOE are
constraint
 Control Cards
Keyword
Title card
Control Energy
Control Hourglass
Control shell
Control Termination
Control Timestep
Database binary D3plot
Database option
 Actual and FEA model

Experimental model LS-Dyna model

Impacting plate

Thin walled tube

Base rigid plate

Schematic representation only

 Parameters consider for convergence
study
Quasi static analysis

Factors consider for study

Number of through
Element formulation Type of hourglass thickness integration Mesh size
points(NIP)
Flow chart of convergence parameter
Quasi static
analysis

Element
formulation

1 2 16 26

Type of
hourglass(IHQ)

1 2 3 4 5 6

NIP

3 5 7 9

Mesh size (mm)

1 2 3 4 5 6 7 8

Coefficient of
friction

Fig : Above fig showing flow chart for one option only to avoid complexity
DOE method
 First case consider for simulation
Quasi static analysis -
• Element formulation = 16
• NIP = 5
• Types of hourglass = 4 (With hourglass coefficient = 0.03)
• Mesh size = 3mm
 Factors consider for study
For each simulation Force Vs Deflection curve is extracted from simulation.
Base on the curve following crashworthiness criteria are used to evaluate
crashbox performance –
Energy absorption(EA) - Total amount of energy absorbed by a crashbox,
area under force-deflection curve.
Specific energy absorption(SEA) – energy absorption per unit mass.(EA/M)
Peak crushing force(PCF) - is the maximum reaction force generated during
the impact.
Mean crushing force(MCF) – EA/deltamax
Numerical result obtained for first
simulation