hm titorials

RD-3150: Seat Model with Dummy using HyperCrash

Introduction

This tutorial presents the different steps involved in building a simple Sled model using HyperCrash pre-processing tool.

Exercise

Step 1: Model Import

Set user profile, units and interface.1. Open HyperCrash 11.0.2. For User Profile, select RADIOSS V10.3. For Unit System, select N_mm_s_T.4. For User Interface Style, select New.5. Click Run.

Step 2: Import the seat model and merge all components, floor, seatbelt and foam block.

1.Click File > Import > RADIOSS....

2. Select the file SEAT__00D00.rad.3. Click OK.

Step 3: Model Merging1. From the File menu, click Import, select RADIOSS,

HyperCrash message window prompt.

2. Click Merge.3. Select the file FLOORD00.rad.4. Click OK.5. Click the Set all to button and input the value as: 100000.

6. Then click the Set all to button again, this will offset the numbering of all the entities.7. Click Merge to merge the floor model.8. Redo the steps 1 to 7 for the cushion model:• File: FOAMD00.rad• Set all to offset: 2000009. Redo the steps 1 to 7 for the seatbelt model:• File: BELTD00.rad• Set all to offset: 300000

Step 4: Model Hierarchy1. In the Tree, select the subset of the seat named Seat model (300005).2. In the pop-up menu, right-click the mouse button and select Change Name.

3. Enter the name Seatbelt in the Change Name window.4. Click Ok.

5.Click on any item on the tree, click on right mouse button and in the pop-up menu, select New Assembly.

6. Enter the name Seat and click Ok.

7.Select the parts Seat plate, Backseat plate, Feet, Seat frame, and Backseat frame using the Shift or Ctrl keys.

8. Press the middle mouse button and drag the selected parts into the assembly Seat.9. Select the tree root (Seat) and click on the right mouse button.10. In the pop-up menu, select List Selection.

The Selection List dialog opens.

11. In the displayed window, check if all parts have properties and materials.12. Close the window and Export the model to save.

Step 5: Connection

To add the feet of the seat and the seatbelt anchorage point to the floor rigid body.

1. From the Mesh Editing menu, choose Rigid Body > Modify.2. Select the rigid body: Floor.

3. Click See selected rigid bodies ( ).

4. Click on Display All and then on Left View (F11).

5.Toggle the radio button Added and select all the nodes of the seat feet and the anchorage points of the seatbelt using the node selections tools.

6.Select the Properties sub-panel and activate the Time history for the Master node and Rigid body.

7.Click Save > Close.

Connect Seat Cushion to the seat frame with a tied interface (type2).

1. From the LoadCase menu, select Contact Interface > Create/Modify.2. Under Choose Contact, click on Kinematic condition (Type 2) twice to activate.

3.Click the Slave radio button and select the nodes of the seat cushion facing the seat frame as shown below using the node selection tools.

Tips: Press the letter P for non-perspective view, if needed.

Press SHIFT and draw a closed polygon window around the nodes to select. When finished, release the SHIFT key.

4. Display Seat Assembly in the Tree.5. Click Master and select all the elements of the seat assembly facing the seat cushions.

Slave Master

6. Select the Properties sub-panel and set the interface name as seat cushion fixation.7. Click Save.

8.From the LoadCase menu, select Contact Interface > Check.

The created interface should be displayed with green text, as shown below. Otherwise, the interface has to be improved.

9. Click Close.10. Export the model to save.

Step 6: Dummy positioning1. From the Safety menu, select Dummy Positioner.2. From the Dummy model list pull-down menu, select New dummy.

A Dummy Mng panel opens.3. In the Dummy Mng panel, select the File sub-panel.4. Select the file H350R12BD00.

The dummy model is displayed in the small graphic window.5. Click Validate.6. Click the Set all to button and set the value to 400000.7. Click the Set all to button again, to offset the numbering of all entities.8. Click OK to merge the Dummy model.

9.Click Import in the dummy positioning window and select the file H350R12B_Position.M00.

Note:H350R12B_Position.M00 contains all parameters for the automatic dummy positioning.

10. Close the Dummy positioner and Export the model to save.

Step 7: Seatbelt setting1. From the Safety menu, select Belt Generator.

2. Enter the name Upper belt and click OK to validate.

3. Click Seat belt reference points ( ).

4.Click Add nodes by picking ( ) and select three nodes, as shown in the following image (red arrows).

5. Click Yes on the right corner and Ok to validate the node selection.

6.Click Add/Remove body part ( ) and select the parts: torso, pelvis, upper legs, and the seat cushion fabric, as shown in red in the image.

7. Click Yes to validate the selection. 8. Set the Gap value to 5.00 mm.9. Set the Nb elems in length as 80.10. Set the Nb elems in width as 4.11. Toggle Transversal direction at the first node to X.12. Toggle Transversal direction at the last node to X.

13. Click Choose material in database ( ) and select the material file BELT.mat. 14. Then click Save.

15. Click Choose property in database ( ) and select the property file BELT.prop.16. Then click Save.17. Click the Preview button to display the proposed seat belt.

Some intersections may exist between the seat cushion and the seat belt.18. At the top of the panel, from the Options drop-down menu, click Automatic fitting.

19. Click Fit Automatic ( ).

20.Using the different tools available in this menu, remove the intersections and penetrations between the seatbelt and the seat cushion.

21. Click Save.

22.Click Close to close the de-intersection/de-penetration page and come back to the seatbelt creation page.

23. Click Save again.24. Redo the same operations in order to create the lower belt:

Select nodes as shown in arrows:

Select the parts: pelvis, upper legs and seat cushion fabric.

25. Click Preview > Save > Close.26. Export the model to save.

Step 8: Seatbelt Anchorage

During the seatbelt creation, one rigid body is created on each end of the seatbelt. The loose ends of the anchorage points (springs & truss) should be included in the seatbelt rigid body.1. From the Mesh Editing menu, select Rigid Body > Modify.2. Select the rigid body Upper belt_RBody_first_node.

3. Click See selected rigid bodies ( ).4. Click Added.

5. Display the entire model using view all icon ( ) .

6. Add the nearest seatbelt spring node using node selection by box ( ).

7.Select the Properties sub-panel and activate the Time history for the Master node and the Rigid body.

8. Click Save.9. Re-do the same operations for the three other rigid bodies of the seatbelt:

Upper belt_RBody_last_node

Lower belt_RBody_first_node

Lower belt_RBody_last_node10. Click Close > Export the model to save.

Step 9: Contact interfaces

Seatbelt vs Dummy

During the seatbelt creation, two contact interfaces between the seatbelt and the dummy have been created. You will need to check and remove any remaining intersections and penetrations.

1.From the LoadCase menu, select Contact Interface > Create/Modify.

2. Select interface BELT ID 400039.

3.

Click See selected ( ) to display it. In the selection add the upper elements of the Fabric backframe and Backseat to the master as shown in the picture to avoid the seatbelt to penetrate them during contact.

4. Select the Properties sub-panel.

5. Set the Coulomb friction value to 0.3.6. Click Save.7. Select interface BELT ID 400040.

8. Click See selected ( ) to display it.9. Select the Properties sub-panel.10. Set the Coulomb friction value to 0.3.11. Click Save.12. Select interfaces BELT ID 400039 and BELT ID 400040.

13. Click Check penetration selected interfaces ( ).14. In the Quality panel remove the existing intersections and penetrations.15. Click Close in order to come back to the Contact Interface panel.16. Export the model to save.

Seat structure

Creation of Self-Impact between different parts of the Seat.1. In the Tree window, select subsets Seat, Floor and Foam.


3. Select interface: Multi-usage (Type 7).4. Click Self-impact.

5. In the Added panel, click on ( ) Add selected parts of Tree.

6. Click on to have Solid external face only.7. Select the Properties sub-panel.

8. Set the interface Title to Self impact seat structure.9. Set the Coulomb friction to 0.2.10. Set the Gap/element option to Variable gap.11. Click Save.12. Select the self impact interface in the list.

13. Click Check penetration selected interfaces ( ).

Some penetrations exist between the seat cushion and the seat structure.14. Switch to the Tree window, and select the subset named Seat.

15. Switch to Quality window and click on Fixed part ( ).

16. Press the ESC key to remove all selected parts.

17. Click on Add selected parts of tree ( ).

18. Click on Select All ( ) and click Depenetrate Auto ( ).Note: Only the nodes of the seat

cushion are moved. The seat parts are fixed.

19. Click Close twice.20. Export the model to save.

Dummy vs Seat

Creation of Interface between Dummy and Seat.


2. Select interface Multi usage (Type 7).

3. Click Slave.4. In the Tree window, select the Foam subset - the two cushion parts only.

5. Switch back to the Interface panel and click ( ) Add selected parts of Tree.6. Again switch to the Tree window.7. Select the subset named HYBRID III 50% DUMMY FINE MESH V_1.2.8. Switch back to the Contact interface panel.

9. Click Master > Add Selected part of Tree ( ).

10. Select the Properties sub-panel.

11. Set the interface Title to Dummy - Seat.12. Set the Coulomb friction to 0.3.13. Set the Constant gap value to 3.00mm .14. Click Save > Close.15. Export the model to save.

Dummy vs Floor

Creation of an interface between dummy feet and the floor.


2. Select Interface type Tied with void (Type 10).3. Set the dummy feet as slave nodes.4. Click Slave and select the parts of the dummy feet.5. Set the floor as master surface.6. Click Master and select the floor.

7. Select the Properties sub-panel.8. Set the interface Title to Feet – Floor. 9. Set the Gap for impact activation to 3.0 mm.10. Click Save > Close.11. Export the model to save.

Seat Deformer

Modifying the seat cushion mesh to conform to the dummy using the Seat Deformer tool.

Step 1: Select model direction1. From the Safety menu, select Seat Deformer.2. Set the Gap= value to 3.00 mm (the same as defined in the interface).

Make sure the Dummy is oriented in the same orientation as the schematic.3. Set X- for the Front Direction.4. Set Z+ for the Top Direction.

5. Click Accept.

Step 2: Select Seat Parts1. Using the model display tools, display only the parts with solid elements.2. Select both parts of the seat foam.

3.Click Accept.

Step 3: Select Dummy Parts1. Switch to the Tree window.2. Select the subset named HYBRID III 50% DUMMY FINE MESH V_1.2.3. Switch back to the Seat Deformer panel.

4. Click Add Selected part of Tree ( ).5. Click Accept.

Step 4: Select Seat-Back Nodes1. Switch to the Tree window.2. Select the back frame cushion only.3. Switch back to Seat Deformer and change the Select by drop-down list to Part .

4. Click Add Selected part of Tree ( ).

5. Click Accept.

Step 5: Select Fixed Nodes1. Toggle to Select.

2.Using the node selection tools, use the select by box tool ( ) to select the back and bottom nodes of the cushion (not fabric).

Tips: On the keyboard, press P for non-perspective view to facilitate the selection.

Press SHIFT and draw a closed polygon window around the nodes. When done, release the SHIFT key.

3. Click Accept.

HyperCrash now deforms the seat.4. Click Close.

After the seat deformation, check if any initial penetrations remain between the seat and the dummy.


2. Select interface Dummy – Seat.

3. Click Check penetration selected interfaces ( ).

Penetrations exist between the seat beam and the dummy.

4. Click Select All ( ).

5. Click Highlight by Vector ( ).

6. Click Fixed part ( ) .7. Press the ESC key to remove all selected parts.

8. Click Fixed part ( ) and then select the displayed parts of the dummy.

9. Click Depenetrate Auto ( ).

Only the nodes of the seat cushion are moved. The parts of the dummy are fixed.10. Click Close > Export the model to save.

Loadcase setting

Step 10.1: Initial velocity

Update the initial velocity defined in the model to include all the nodes in the model.1. From the LoadCase menu, select Initial Velocity > Modify.2. Select the initial velocity All in the list.

3. Click See selected initial velocity ( ).

4. Select all nodes of the model using the selection tools ( ).

5. Change the initial velocity from –10000 to –13000 mm/s.

6. Click Save > Close.7. Export the model to save.

Step 10.2: Imposed velocity

Update the imposed velocity on the floor to decelerate the car.1. From the LoadCase menu, select Imposed Velocity > Modify.2. Select Imposed velocity in the list.

3. Click See selected imposed velocity ( ).

The floor rigid body is displayed on the screen. The imposed velocity is defined on its master node.

4. Select the Properties sub-panel. 5. Click Function and check if the initial value of the function is the same as the initial velocity.

6. Click Save > Close.7. Export the model to save.

Step 10.3: Boundary conditions

To simulate the Sled Test, you need to constrain all degrees of freedom on the floor except X-direction.

1.From the LoadCase menu, select Boundary Condition > Modify.

2. Select the boundary condition in the list.

3. Click See selected boundary condition ( ).

The floor rigid body is displayed on the screen. The boundary condition is defined on its master node.

4.Fix the degree of freedom for Ty, Tz, Rx, Ry, and Rz.

5. Click Save > Close.

6. Export the model to save.

Time history data setting

Step 11.1: Nodes

1.From the Data History menu, select Node > Modify.

2. Select the node group H350MEF2D00_th_nodes.

3. Click See selected th ( ).

These are the nodes of the dummy rigid bodies.4. For each node of the group:• Select the node in the list.

• Click See selected node ( ).• Enter a name in the field Node name as shown in the table.

• Click Ok.5. When all labels are defined, click Save > Close.6. Export the model to save.

Step 11.2: Parts

1.From the Data History menu, select Part > Modify.

2. Select the second and third part group on the list.

3. Click Delete selected th ( ). 4. Answer Yes to the question in the main window (Yes, No, Cancel).

The selected parts groups are deleted from the model.5. Select the remaining part group in the list.

6. Click See selected th ( ).7. Go to the Tree panel and select the root of the tree.

8. Switch back to the Data History panel and click Add parts by tree selection ( ).

9. Click Save > Export the model to save.

Step 11.3: Interfaces

To Add all interfaces to Time History.


2. Select all interfaces in the list.3. Right-click the mouse button, and in the pop-up menu, select Time History > Add.

Step 11.4: Final Check1. Go to Quality Module.2. Select Check All Interfaces.3. Make sure there are no intersections and initial penetrations; if so, fix them.4. Click Close.5. Go to Mesh Editing and clean so all the unused materials and properties are removed.

Step 12: Model saving1. From the File menu, select Export > RADIOSS….

2. Enter a name for the model in the file output window and click OK.

3. Write relevant information regarding your model in the Header window.4. Click Save Model.5. In the Write Engine File window, set the Run number to 1.

6. Set the Final time to 0.1001 s.7. Switch the Constant nodal time step to On.8. Set Scale factor to 0.67.9. Set Minimum time step to 0.5e-6 s.10. Set the Animation Time frequency to 0.005 s.11. In the field labeled Print time history files every: enter 0.0001 s.12. Select the Anim sub-panel and activate all options.

13. Click Write Engine File.14. With a text editor, open the file MODEL_00D01 and add the following lines:

#/DT/SHELL/DEL0.000000e+000 1.000000e-009#/MON/ON

The first two lines will be used to delete elements from the beginning. The last command is used to print the calculation time in the listing file.

The model is now ready to be computed.

file:///C:/Program%20Files/Altair/11.0/help/hwtut/hwtut.htm?rdtut_for_hypercrash.htm

CRASH-1000: Defining LS-DYNA Model and Load Data, Controls, and Output

In this tutorial, you will learn to:

•View DYNA keywords in the Engineering Solutions - Crash – LS-DYNA user profile as they will appear in the exported DYNA input file

• Understand part, material, and section creation and element organization• Create sets• Create velocities• Create nodal single point constraints• Create contacts• Define output and termination• Export models to LS-DYNA formatted input files

Exercises

This tutorial contains the following exercises:

Exercise 1: Define Model Data for the Head and A-Pillar Impact Analysis

Exercise 2: Define Boundary Conditions and Loads for the Head and A-Pillar Impact Analysis

Exercise 3: Define Termination and Output for the Head and A-Pillar Impact Analysis

Section 1: Define Model Data

Relation of *PART, *ELEMENT, *MAT, and *SECTION to Each Other

*ELEMENT EID PID

*PART PID SID MID

*SECTION SID

*MAT MID

A *PART shares attributes such as section properties (*SECTION) and a material model (*MAT). A group of elements (*ELEMENT) sharing common attributes generally share a common part ID (PID). The figure below shows how the keywords *PART, *ELEMENT, *MAT and *SECTION relate to each other. A unique PID assigns a material ID (MID) and a section ID (SID) to an element.

The figure below shows how the keywords *ELEMENT, *PART, *SECTION, and *MAT are organized.

*ELEMENT EID PID Elements are organized into a component collector

*PART PID SID MID Component collector’s card image

*SECTION SID Property collector with a property card image. Assign a property to a *PART by pointing to the property collector in the component collector’s card image.

*MAT MID Material collector with a material card image. Assign the material to the *PART by associating the material collector to the component collector.

Component, property and material collectors are created and edited from the Collectors panel.

View DYNA Keywords in Engineering Solutions

An Engineering Solutions card image allows you to view the image of keywords and data lines for defined DYNA entities as interpreted by the loaded template. The keywords and data lines appear in the exported DYNA input file as you see them in the card images. Additionally, for some card images, you can define and edit various parameters and data items for the corresponding DYNA keyword.

Card images can be viewed using the Card Editor panel which can be access from the Card Editor icon in the toolbar, or from the right-click context menus in the Model Browser and Solver Browser.

Create *MAT

In Engineering Solutions, a *MAT is a material collector with a card image. To relate it to a *PART, the material collector is associated to a component collector. A material collector can be created from the Model Browser, Solver Browser or by selecting the Model menu and choosing Material > Create.

Update a Component’s Material

Update any component with any material from the Component Collectors panel, update subpanel.

Material Table Utility

This utility allows you to do the following:• View a list of all existing materials in the model and attributes for them.• Create, edit, merge and check for duplicate materials.

This utility is located in the the Model menu.

Create *SECTION

In Engineering Solutions, *SECTION is a property collector with a card image. This is created in the Property Collectors panel, create subpanel.

Exercise 1: Define Model Data for the Head and A-Pillar Impact Analysis

The purpose for this exercise is to help you become familiar with defining LS-DYNA materials, sections and parts using Engineering solutions – Crash - LSDYNA.

This exercise comprises of setting up the model data for an LS-DYNA analysis of a hybrid III dummy head impacting an A-pillar. The head and A-pillar model is depicted below.

Head and A-pillar model

This exercise contains the following tasks.• Define the material *MAT_ELASTIC for the A-pillar part and head part.• Define *SECTION_SHELL for the A-pillar.• Define *SECTION_SOLID for the head.• Define *PART for the A-pillar and the head.

Step 1: Load the Crash - LS-DYNA user profile1. From the startup menu, choose Engineering Solutions > Crash - HyperMesh.2. Select the LsDyna profile in Crash and click OK.

Step 2: Retrieve the model file

1. From the toolbar, click the Open Model icon and browse to the file head_start.hm. 2. Click Open.

The model loads into the graphics area.

Step 3: Define the material *MAT_ELASTIC for the A-pillar and head1. Right-click in the Model Browser and pick Create > Material.

The Create material dialog appears.

2. For Name, enter elastic.3. For Card image, select MATL1.4. Click Card edit material upon creation to activate the option.5. Click Create to create the material and edit its card image.6. Click the [Rho] field and enter 1.2 E-6 for the density. 7. For Young’s modulus [E], specify 210.8. For Poisson’s ratio [Nu], specify 0.26.9. Click return to exit the panel.

Step 4: Define property (*SECTION_SHELL) with a thickness of 3.5 mm for the A-pillar1. Right click in the Model Browser and pick Create > Property.

The Create property dialog appears.

2. For Name, enter section3.5.3. In the Type field, select SURFACE.4. For Card image, select SectShll.5. Click Card edit property upon creation to activate the option.6. Click Create to create the property and edit the card.7. For T1, enter 3.5.8. Click return to exit the panel.

Step 5: Define *SECTION_SOLID for the head1. Right click in the Model Browser and pick Create > Property.2. For the Name field, type solid.3. In the Type field, select VOLUME.4. For Card image, select SectSld.5. Click Card edit property upon creation to deactivate the option.6. Click Create to create the property.

Step 6: Define *PART for the A-pillar

MAT_ELASTIC is the material collector named "elastic". *SECTION_SHELL is the property collector named "section3.5".1. Right click on the pillar component in the Model Browser and pick Edit. 2. For Card image, select Part.3. Click the Material tab.4. Click the Assign material option to activate it.5. For Name, select elastic.6. Click the Property tab.7. Click Assign property to activate the option.8. For Name, select section3.5.9. Click Update.

Step 7: Define *PART for the head

*MAT_ELASTIC is the material collector named "elastic". *SECTION_SOLID is the property collector named "solid".1. Right click on the component head in the Model Browser and pick Edit.2. For Card image, select Part.3. Click the Material tab.4. Click the Assign material option to activate it.5. For Name, select elastic.6. Click the Property tab.7. Click the Assign property option to activate it.8. For Name, select solid.9. Click Update to update the component.

The exercise is complete. Save your work to as an .HM file.

Section 2: Define Boundary Conditions and Loads

*SET

With the exception of *SET_SEGMENT, all *SET types are created from the Entity Sets panel, from clicking Tools > Create > Sets. Graphically view a set’s contents with the review function in the Entity Sets panel. *SET_SEGMENT is created from the Contactsurfs panel and is discussed in this chapter.

Exercise 2: Define Boundary Conditions and Loads for the Head and A-Pillar Impact Analysis

The purpose for this exercise is to help you start becoming familiar with defining LS-DYNA boundary conditions, loads and contacts using Engineering Solutions.

This exercise comprises of setting up the boundary conditions and loads data for an LS-DYNA analysis of a hybrid III dummy head impacting an A-pillar. The head and A-pillar model is depicted below.


This exercise contains the following three tasks.• Define velocity on all nodes of the head with *INITIAL_VELOCITY• Constrain the pillar’s end nodes in all six degrees of freedom with *BOUNDARY_SPC_NODE

•Define a contact between the head and A-pillar with *CONTACT_AUTOMATIC_SURFACE_TO_SURFACE

Step 1: Make sure the LS-DYNA user profile is still loaded1. From the menu bar, click Preferences > User Profiles.2. Select Engineering solutions, Crash - LsDyna.

Step 2: Retrieve the model file head_2.hm1. Retrieve the model file, head_2.hm.

2.Take a few moments to observe the model using various visual options available (rotation, zooming, etc.).

Step 3: Create a node set containing all the nodes in the head component1. Click Model > Sets > Nodes > Create.2. For Name, enter Vel_Nodes.3. For Card image, select Node.4. With the nodes selector active, click nodes >> by collector and select the component head.5. Click create to create the set.

6. Click return to close the panel.

Step 4: Define the initial velocity

1.Click BCs > Initial Velocity > Node Set > Create.

2. For loadcol name, enter init_vel.3. Click create/edit to create the load collector and edit its card image.4. In the node set ID [NSID] field, select the entity set Vel_Nodes. 5. For the initial velocity in the global x-direction, VX field, specify 5.6. Click return.7. Stay in the Load Collector panel for the next step.

Step 5: Create a load collector for the constraints to be created1. In the Load Collector panel, in the Name field, enter SPC.2. For creation method, select none.3. Click create to create the load collector.4. Click return to close the panel.

Step 6: Create constraints on the pillar’s end nodes

1.Click BCs > Constraints > Nodes > Create.

2. Leave the entity selector set to nodes.3. Click nodes >> by sets and select the pre-defined entity set nodes for SPC.

Notice the nodes at the pillar’s ends are highlighted.4. Leave all six degrees of freedom, dof1 thru dof6, active.5. Leave the load type as BoundSPC.6. Click create to create the constraints. 7. Click return to close the panel.

Step 7: Define a *SET_SEGMENT for the slave entities, the A-pillar elements1. Click Model > Segments > Segment > Create. 2. For name, type pillar_slave.3. Optionally select a color for the contactsurf.

4.With the elems selector active, click elems >> by collector and then select the pillar component.

5. Click create to create the contactsurf.6. Review the contactsurf to make sure its pyramids are pointing out of the pillar.7. Stay in this panel for the next step.

Step 8: Define a *SET_SEGMENT for the master entities, the head elements1. Select the solid faces subpanel.2. For name, type headmaster.3. For Card image, select setSegment.4. Optionally select a color for the contactsurf.

5.With the elems selector active, click elems >> by collector and then select the head component.

6. Leave the toggle set to nodes on face.

7. Click the yellow nodes selector to make it active. 8. Select three nodes belonging to the same face of a solid element.9. For the break angle, leave it set to 30.10. Click create to create the contactsurf.11. Review the contactsurf to make sure its pyramids are pointing out of the head.12. Click return to close the panel.

Step 9: Create SurfaceToSurface contact interface between pillar and head

1.Click BCs > Contact > Surf to Surf > Create.

2. For Name, type contact.3. Leave Type set to SurfaceToSurface.4. Click create to create the group.5. Stay in the Interfaces panel for the next step.

Step 10: Add the slave and master contactsurfs to the group1. Select the add subpanel.2. For the master type, select csurfs.3. Click the contactsurfs selector and select the headmaster contactsurf.4. Click update in the master: line, to the right of the yellow contactsurfs selector.5. For the slave type select csurfs.6. Click the contactsurfs selector in the slave: line and select pillar_slave.7. Click update in the slave: line.8. Stay in the Interfaces panel for the next step.

Step 11: Edit the group’s card image to define the AUTOMATIC option1. Select the card image subpanel.2. Click edit to edit the group’s card image.3. Under Options, click the toggle to select Automatic. 4. Click return to go back to the Interfaces panel.5. Stay in the Interfaces panel for the next step.

Step 12: Review the group’s master and slave surfaces1. Select the add subpanel.2. For name, select contact.3. Click review.4. Notice the master and slave entities are temporarily displayed blue and red, respectively. 5. Click return to close the panel.

The exercise is complete. Save your work to a HyperMesh file.

Exercise 3: Define Termination and Output for the Head and A-Pillar Impact Analysis

The purpose for this exercise is to help you become familiar with defining LS-DYNA control data and output requests using Engineering Solutions.

This exercise comprises of defining the termination and output for an LS-DYNA analysis of a hybrid III dummy head impacting an A-pillar. The head and A-pillar model is shown in the image below.


This exercise contains the following four tasks.• Specify the time at which LS-DYNA is to stop the analysis with *CONTROL_TERMINATION• Specify ASCII output with *DATABASE_(Option) cards• Specify the output of d3plot files with *DATABASE_BINARY_D3PLOT• Export the model to an LS-DYNA 971 formatted input file

Step 1: Make sure the Crash - LS-DYNA user profile is still loaded

Step 2: Retrieve the model file head_3.hm

Step 3: Specify the time at which you want LS-DYNA to stop the analysis with *CONTROL_TERMINATION1. Click Model > Control Cards to open the Control Cards panel.2. Click next to scroll through the list.3. Select CONTROL_TERMINATION.

A card image pops up.

4. For the termination time of the analysis, ENDTIM, specify 2.5.5. Click return to go back to the Control Cards panel.

Step 4: Specify frequency for animation file output 1. Click Output > Database_Binary > D3PLOT.

2. For the interval between outputs in the D3PLOT file, [DT] field, specify 0.1.3. Click return to go back to the Control Cards panel.

Step 5: Specify frequency for ASCII of time history file output1. Click Output > Database_Extent > Binary.2. For the GLSTAT file, [GLSTAT] field, specify 0.1.

This specifies the output of global data at every 0.1 ms.

3. For the MATSUM file, [MATSUM] field, specify 0.1.

This specifies the output of material energies every 0.1 ms.

4. For the SPCFORC file, [SPCFORC] field, specify 0.1.

This specifies the output of SPC reaction forces every 0.1 ms.5. Click return to go back to the Control Cards panel.6. Click return to close the panel.

Step 6: Export the model as an Ls-Dyna keyword file1. Click File > Export > Solver Deck to open the Export tab.2. Make sure Ls-Dyna is selected as the File type and the appropriate template is selected. 3. Enter the file name as head_complete.key.4. Click Export.

Step 7 (Optional): Submit the LS-DYNA input file to LS-DYNA 9711. From the desktop’s Start menu, open the LS-DYNA Manager program.2. From the solvers menu, select Start LS-DYNA analysis.3. Load the file head_complete.key. 4. Click OK to start the analysis.

Step 8 (Optional): Post-process the LS-DYNA results using HyperView

The exercise is complete. Save your work to an .HM file.

Go to HyperMesh Tutorials

CRASH-1100: Using Curves, Beams, Rigid Bodies, Joints, and Loads in DYNA

In this tutorial, you will learn how to:• Create XY curves to define non-linear materials• Define beam elements• Create constrained nodal rigid bodies • Create joints• Define *DEFORMABLE_TO_RIGID • Define *LOAD_BODY • Define *BOUNDARY_PRESCRIBED_MOTION_NODE• Use the Component Table tool to review the model’s data

Tools

The following tools are covered in this tutorial:• DYNA Tools• Component Table• Curve Editor

The Component Table is part of the Model menu. With this tool, you can view a summary of the model’s parts as well as create and edit parts. Below is a list of the tool's functionality.• Create a list of displayed or all parts and view them in the graphics area• Display parts with same section or material• Rename and renumber parts, sections and materials• Update thickness• Create new parts • Assign sections and materials to parts• Export table to file with comma separated format

In the Component Table window, place the cursor over each button to see an explanation of each button.

Below is a sample image of the Component Table.

The Curve Editor can be accessed by clicking Model > Function > Create Curve from the menu bar.

The Curve Editor is a pop-up window that allows you to view and modify graphed curves in a more intuitive and holistic way than the individual xy plots panels provide.

Below is a list of the tool’s functionality.• Change curve attributes• Change graph attributes• Display curves in the graph area• Create a new curve• Delete a new curve• Rename a curve

Below is a sample image of the Curve Editor.

Exercises

This tutorial contains the following exercises:

Exercise 1: Define Model Data for Seat Impact Analysis

Exercise 2: Define Boundary Conditions and Loads for the Seat Impact Analysis

Exercise 1: Define Model Data for the Seat Impact Analysis

This exercise will help you continue to become familiar with defining LS-DYNA model data using Engineering Solutions.

This exercise is comprised of defining and reviewing model data for an LS-DYNA analysis of a vehicle seat impacting a rigid block. The seat and block model is shown in the image below.

Seat and block model

Step 1: Load the LS-DYNA user profile1. From the startup menu, choose Engineering Solutions > Crash - HyperMesh.2. Select the LsDyna profile in Crash and click OK.

Step 2: Retrieve the model file 1. Browse to the file seat_start.hm.

2.Take a few moments to observe the model using various visual options available in HyperMesh (rotation, zooming, etc.).

Step 3: Create an xy plot

1.Click Model > Functions > Create > Plot.

2. For plot=, enter seat_mat.3. Verify the plot type is set to standard.4. Leave the like = field empty.

When an existing plot is selected, the new plot adopts its attributes.5. Click create plot.6. Click return.

Step 4: Input data from a file to create two stress-strain curves

1.Click Model > Functions > Create > Read Curves.

2. For plot =, leave it set to seat_mat.3. Click browse... and locate the file named seat_mat_data.txt.4. Click input to input the file.5. Notice two curves are created and are named 0.001 strain rate for steel (curve1) and 0.004

strain rate for steel (curve2).6. Click return.

Step 5: Create a table1. From the Model menu, click Table > Create.2. Enter Steel_flow_stress_data as a name for the table.

3.In the card image, in the [ArrayCount] field, specify 2.

This is the number of strain rate values to be specified.

4. For the strain rate VALUE(1) field, specify 0.001.5. For the strain rate VALUE(2) field, specify 0.004.6. Click on CurveId(1) and select curve1.7. Click on CurveId(2) and select curve2.8. Click return to exit the panel.

Step 6: Create the non-linear material (*MAT_PIECEWISE_LINEAR_PLASTICITY)1. Click View > Browsers > HyperMesh > Solver to open the Solver Browser.

2.Right-click anywhere in the Solver Browser and click Create > *MAT > MAT (1-50) > 24-*MAT_PIECEWISE_LINEAR_PLASTICITY.

3. For Name: type steel.4. Set Type = Elastic-Plastic.5. Set Card image = MAT_24 and click OK.6. For density [Rho] field, specify 7.8 E-6.7. For Young’s Modulus [E] field, specify 200.8. For Poisson’s ratio [NU] field, specify 0.3.9. For yield stress [SIGY] field, specify 0.25.10. For the *DEFINE_TABLE id [LCSS] field, select curve3 (id=5).11. Click return to close the card image.

Step 7: Update the base_frame and back_frame components with the new non-linear material1. Click Model > Component Table.2. From the Table menu, click Editable.3. Select the components base_frame by clicking on its row to highlight it. 4. For Assign Values:, select Material name.5. For HM-Mats:, select steel.6. Click Set and click Yes to confirm.7. Repeat steps 3 - 6 for the component back_frame.8. Close the Component Table.

Steps 8-10: Create a beam element to complete the seat’s back_frame connection to the side_frame on the left side

Step 8: Restore a pre-defined view

1. On the toolbar, click the User Views icon.

A dialog pops up.2. Click restore1 to see the beam view.

Step 9: Set the current component to beams

1.In the Model Browser, right-click on the beams component and select Make Current to set the beam component as the current collector.

Step 10: Create the beam1. Click Mesh > Create > 1D Elements > Bars to open the panel. 2. Click the leftmost switch and select node.

A direction node is selected later to define the beam’s section orientation.3. Click the Node A selector to make it active. 4. Select the center node of the left nodal rigid body for Node A.

Node B is active now.5. Select the center node of the right nodal rigid body for Node B.6. Select any non-center node of one of the nodal rigid bodies for the direction node.

Notice the beam is created.7. Click return to close the panel.

Step 11: Display node IDs for ease of following the next steps

1. Click on the numbers icon to open the Numbers panel.2. Change the entity selector set to nodes.3. Click nodes and select by id. Enter 425-427, 431 and press Enter.4. Activate the display checkbox, and click on to display the IDs.5. Click return.

Step 12: Set the current component to welding

1.In the Model Browser, right-click on the welding component and select Make Current to set the welding component as the current collector.

Step 13: Create the rigid connection between nodes (*CONSTRAINED_NODAL_RIGID_BODY)

1.Click Connections > Nodal Rigid Body > Create.

2. Set nodes 2-n to multiple nodes.3. Select the beam’s free end for node1.4. Select nodes 425, 426, 427 and 431 for nodes 2-n. 5. Leave the attach nodes as set option active.6. Click create to create the nodal rigid body.7. Click return.

A *CONSTRAINED_JOINT_STIFFNESS is not created; it is not needed for this joint to work.

Step 14: Display node IDs for ease of following the next steps

1. Click on the numbers icon to open the Numbers panel.2. Leave the entity selector set to nodes.3. Click nodes and select by id. Type 1635, 1636 and press Enter.4. Activate the display checkbox, and click on to display the IDs.5. Click return.

6.From the toolbar, click the Wireframe Elements (Skin Only) icon to change to standard graphics mode.

Step 15: Activate coincident picking

1.Click Preferences > Graphics.

2. Activate coincident picking.3. Click return.

Step 16: Set the current component to joint

1.In the Model Browser, right-click on the joint component and select Make Current to set it as the current collector.

Step 17: Create a revolute joint between two nodal rigid bodies (*CONSTRAINED_JOINT_REVOLUTE)

The rigid bodies must share a common edge along which to define the joint. This edge, however, must not have the nodes merged together. The two rigid bodies will rotate relative to each other along the axis defined by the common edge.

1.Click Connections > Joints > Element > Create.

2. Set the joint type to revolute.

node1 is active.3. Click on node 1635.

Notice the coincident picking mechanism displays two nodes – 1635 and 1633.

4.Move the mouse to node 1635 in the coincident picking display and click on it to select it for node 1 in rigid body A.

node2 is now active.

5.Click on node 1635 again to see the coincident picking mechanism and select node 1633 for node 2 in rigid body B.

node3 is now active.6. Click on node 1636.

Two coincident nodes are displayed – 1636 and 16347. Select node 1636 for node 3 in rigid body A.

node4 is now active.8. Select node 1634 for node 4 in rigid body B.9. Click create to create the joint.10. Click return.

Steps 18-20: Define *DEFORMABLE_TO_RIGID to set up the moving seat as rigid until the time of impact with the block, to reduce computation time

Step 18: Create an entity set that contains the components base_frame, back_frame, and cover1. Click Model > Sets > Part > Create.2. For name =, enter set_part_seat.3. For card image, select Part

Notice the entity selector is set to comps.

4.Click the yellow comps button and select the base_frame, back_frame and cover components.

5. Click create to create the set.6. Click return.

Step 19: Define *DEFORMABLE_TO_RIGID to switch the deformable seat to rigid at the beginning of the analysis

1.Right click in the Solver Browser and pick Create > *DEFORMABLE_TO_RIGID > *DEFORMABLE_TO_RIGID.

2. For Name:, enter dtor and click OK to create the card.3. Click the part set ID, [PSID] button twice and select set_part_seat. 4. Click the master rigid body, [MRB], button twice and select back_frame.5. Click return.

Step 20: Create *DEFORMABLE_TO_RIGID_AUTOMATIC to switch the rigid seat to deformable when contact between the seat and block is detected

1.Right click in the Solver Browser and pick Create > *DEFORMABLE_TO_RIGID > *DEFORMABLE_TO_RIGID_AUTOMATIC.

2. For Name:, type dtor_automatic and click OK to create the card.3. For the unique set number for this automatic switch set, [SWSET], enter 1.4. For the activation switch code [CODE] select 0.

The switch will take place at [TIME1].

5. For [TIME1] enter 175.

The switch will not take place before this time.6. Activate R2D_Flag in the menu area.

On export, the number of rigid parts to be switched to deformable is written to the R2D field (card 2, field 6). This number is based on the number of parts in the entity set you select next.

7. Move the scroll bar on the left side of the card image down to see [PSIDR2D].8. Click the [PSIDR2D] button twice and select set_part_seat.9. Click return.

Steps 21-25: Review the model’s component data using the Model Browser, Solver Browser or Component Table toolUsing the Model Browser approach:

Step 23: Display only parts with a particular material (Ex: steel)

1. In the Model Browser, click on the Material View icon .

2.Highlight the material steel, then right click on it and choose isolate to see only components that have the selected material assigned.

3.

To review several materials, click on the isolate icon then select a material and scroll through the material using the arrow keys in the model browser. The corresponding parts are automatically isolated in the view.

4. Follow the above steps to select components using the By Properties option.

Step 24: Display all components

1. In the Model Browser, click on the Material View icon .

Step 25: Rename a part

1. In the Model Browser, click on the Component View icon .

2.Select the part to rename and right click on it. Choose rename from the extended menu options and the becomes editable to enter a new name.

Notice the part's new name in the Solver and Model Browser.

Step 26: Renumber a part ID1. In the Model Browser, right-click on the Part ID field. 2. Enter a number that does not conflict with the existing part IDs.3. Click Yes to confirm.

Using the Solver Browser approach:

Step 23: Display only parts with a particular material (Ex: steel)1. Expand the Materials folder to see all available materials in the model.2. Right-click on the material Steel and select Isolate from the menu.3. Complete steps 1 and 2 to select components based on properties using the *section folder.

Step 24: Display all components

1. In the Solver Browser, click on the Material View icon .


1. In the Solver Browser, click on the Component View icon .

2.Select the part to rename and right click on it. Choose rename from the extended menu options and the becomes editable to enter a new name.


Step 26: Renumber a part ID1. In the Model Browser, right-click on the Part ID field. 2. Enter a number that does not conflict with the existing part IDs.3. Click Yes to confirm.

Using the Component Table approach:

Step 23: Display only parts with a particular material (Ex: steel)1. Click Tools > Component Table.2. From the Display menu, click By Material.3. Select material steel and click proceed.

Notice that the GUI and the Component Table show only those components with material steel assigned. All other components get turned off.

5.Follow the above steps to select components using the By Properties and By thickness option.

Step 24: Display all components1. From the Display menu, click All.2. Notice now that the GUI shows all components of the model.


1.From the Table menu, click Editable to make the table editable. (All columns with a white background can be edited. Ex: Part name, Part id, Thickness etc.)

2. Click on any part name field to edit it.3. Click Yes to confirm.


Step 26: Renumber a part ID1. Click on the Part Id field.2. Type a number that does not conflict with the existing part IDs.3. Click Yes to confirm.


Step 27: Review the model’s data using the Solver Browser

The created solver entities are listed in the corresponding folder in Solver Browser. Each entity has the following options Show, Hide, Isolate, and Review to help user navigate through the model1. Select dtor in the *DEFORMABLE_TO_RIGID folder2. Right-click and choose Isolate to show only the entities that are referred in this keyword.3. Right click and choose Review to highlight the entities.

4.Select the folder *BOUNDARY, right-click and select Show. The entities on which the loads in the folder are defined are displayed, as well as the load handles.

The exercise is complete. Save your work to an .HM file.

Exercise 2: Define Boundary Conditions and Loads for the Seat Impact Analysis

This exercise will help you continue to become familiar with defining LS-DYNA boundary conditions and loads using Engineering Solutions.

In this exercise, you will define boundary conditions and load data for an LS-DYNA analysis of a vehicle seat impacting a rigid block. The seat and block model is shown in the image below.

Seat and block model

This exercise contains the following three tasks.• Define gravity acting in the negative z-direction with *LOAD_BODY_Z• Define the seat’s acceleration with *BOUNDARY_PRESCRIBED_MOTION_NODE• Export the model to an LS-DYNA 971 formatted input file and submit it to LS-DYNA

Step 1: Make sure the LS-DYNA user profile is still loaded1. Click Preferences > User Profiles, or click the User Profiles icon.2. Select Engineering Solutions > Crash > LsDyna.

Step 2: Retrieve the model file 1. Retrieve the model file, seat_2.hm.

2.Take a few moments to observe the model using various visual options available (rotation, zooming, etc.).

Step 3: Define gravity acting in the negative z-direction with *LOAD_BODY_Z

1.Click BCs > Gravity > Create > Parts.

2. For Name:, enter gravity.

3. Click on the Z direction checkbox. 4. Click on the load curve LCID field twice and select the curve named gravity curve.5. For the load curve scale factor [SF], specify 0.001.6. Click return.

Steps 4-5: Define the acceleration for the seat

Step 4: Create a load collector for the acceleration loads to be created1. Right click in the Model Browser and pick Create > Load Collector. 2. For Name:, type accel.3. For Card image:, select none.4. Optionally, select a Color for the load collector.5. Click create to create the load collector.6. Click return.

Step 5: Create acceleration loads on nodes1. Click BCs > Imposed acceleration > Node > Create.2. With the nodes selector active, select nodes and select by sets.3. Select the pre-defined entity set accel_nodes.4. Click on Curve and select the curve acceleration curve.

This is predefined curve that defines acceleration as a function of time.

5. For magnitude, specify 0.001.

This is the scale factor the Curve Y axis values; the curve specified in the previous step for the acceleration loads.

6. For the direction selector, select x-axis.

This is the x-translational degree of freedom.

7. For the magnitude% =, specify 1.0E+7.

This is the scale factor for the graphical representation of the acceleration loads. It does not affect the actual acceleration value.

8. Click create to create the acceleration loads.9. Click return.

Step 6: Export the model to an LS-DYNA 971 formatted input file1. Click File > Export > Solver Deck.2. Make sure the template field shows Ls-Dyna.3. Enter the File name: as seat_complete.key.4. Click Export.

Step 7 (Optional): Submit the LS-DYNA input file to LS-DYNA 9711. From the Start menu on your desktop, open the LS-DYNA Manager program.2. From the solvers menu, select Start LS-DYNA analysis.3. Load the file seat_complete.key. 4. Click OK to start the analysis.

Step 8 (Optional): View the results in HyperView

The exercise is complete. Save your work as an .HM file.

CRASH-1200: Model Importing, Airbags, Exporting Displayed, and Contacts using

DYNA

In this tutorial, you will learn how to:• Define *AIRBAG_WANG_NEFSKE for the airbag mesh geometry

•Define an initial velocity of 3 mm/ms in the negative x-direction for the head with *INITIAL_VELOCITY_GENERATION

•Define a contact between the airbag and head with *CONTACT_AUTOMATIC_SURFACE_TO_SURFACE

• Define *CONTACT_AIRBAG_SINGLE_SURFACE for the airbag• Define a contact between the plate and the airbag with *CONTACT_NODES_TO_SURFACE

Import a DYNA model

Warning and Error Messages

On import of a DYNA model, any warning and error messages are written to a file named dynakey.msg or dynaseq.msg, depending on the FE input translator used. This file is created in the same folder from which Engineering Solutions is started.

Unsupported Cards

On import, the few DYNA cards not supported by Engineering Solutions are written to the unsupp_cards panel. This panel can be accessed from the menu bar by clicking Setup > Control Cards. The unsupported cards are exported with the remaining model.

Care should be taken if an unsupported card points to an entity in Engineering Solutions. An example of this is an unsupported material referenced by a *PART. Unsupported cards are stored as text and pointers are not considered.

LSTC Dummy Files

You can read LSTC Hybrid III dummy files into Engineering Solutions by first converting the tree file to FTSS/ARUP tree file format.

Include Files

*INCLUDE is supported. From the menu bar, click File > Import. Use the options to merge, preserve or skip include files. When include files are read, the IDs of non-existing entities are maintained and these IDs are not used for new entities.

Export Displayed

From the Export tab, you can select the Displayed option to export only displayed nodes and elements. Only model data associated to the displayed nodes and elements are exported. This model data includes materials and their associated curves, properties, portions of contacts, and output requests.

Create and Review Contacts

The table below describes how all slave and master set types are created and specified in contacts.

Slave and master set type

DYNA card Panel used to create card

Equivalent type in Interfaces panel, add subpanel

EQ. 0: set segment id *SET_SEGMENT set_segment (contactsurfs) or …

csurfs

Interfaces, add subpanel

entity

EQ. 1: shell element set id

*SET_SHELL_Option Entity Sets or… sets


entity

EQ. 2: part set id *SET_PART_LIST Entity Sets or… sets


comps

EQ. 3: part id *PART Collectors comps

* EQ. 4: node set id *SET_NODE_Option Entity Sets or… sets


entity

* EQ. 5: include all Interfaces, add subpanel

all

* EQ. 6: part set id for exempted parts

*SET_PART_LIST Interfaces, add subpanel and then card image sub-panel

sets

* For slave surface only

Add subpanel

While the Interfaces panel, add subpanel has several master and slave types - comps, sets, entity, etc. - to choose from in order to specify the DYNA master or slave set for a *CONTACT, only the valid master and slave types are selectable for the particular contact you are creating.

When the master or slave type is set to comps and only one component is selected, the DYNA type is 3, part ID, and *PART is created. When multiple components are selected, the DYNA type is 2, part set ID, and *SET_PART_LIST is created.

When the master or slave type is set to sets, only those sets valid for the particular contact you are creating are selectable. For example, for *CONTACT_NODES_TO_SURFACE, only a list of node sets is available for slave; you will not see a list of other set types, like element or part sets.

Review Contacts

You can review contacts with the review button in the Interfaces, add subpanel.

Exercise: Define Airbag, Velocity, and Contacts for the Airbag Analysis

This exercise will help you become familiar with defining LS-DYNA airbags using Engineering Solutions. It will also help you continue to learn how to define LS-DYNA loads and contacts using Engineering Solutions.

In this exercise, you will define an airbag, velocity, and contacts for an LS-DYNA analysis of a head impacting an inflating airbag. The head and airbag model is shown in the image below.

Head and airbag model

Step 1: Load the LS-DYNA user profile1. From the startup menu, click Engineering Solutions > Crash - HyperMesh.2. Select LsDyna.

Step 2: Import the LS-DYNA model1. From the menu bar, File > Import > Solver Deck. 2. In the File: field, browse to the file airbag_start.key.3. Click Import.

Steps 3-5: Define *AIRBAG_WANG_NEFSKE for the airbag mesh geometry

Step 3: Create a set of parts containing the AirbagFront and AirbagRear components

1.Click Model > Set > Part > Create.

2. For name =, type airbag_set.3. For card image, select Part.4. Click on comps and select the components AirbagFront and AirbagRear.5. Click create to create the set. 6. Click return to close the panel.

Step 4: Define the airbag (*AIRBAG_WANG_NEFSKE)

1.Click Safety > Airbag > Create.

2. For Name:, type airbag. 3. Set the card image field to airbag. 4. With the set selector active, select the entity set airbag_set.

The parts in this set define the airbag’s geometry.5. Click create to create the card.6. Click edit to edit card image of the control volume.

7.Enter the following data in the card image.

Field Value Parameter description

CV 1023.0 Heat capacity at constant volume

CP 1320.0 Heat capacity at constant pressure

T 780.0 Temperature of input gas

LCMT curve id 1 Load curve specifying input mass flow rate

C23 1.0 Vent orifice coefficient

LCA23 curve id 2 Load curve defining vent orifice area as a function of pressure

CP23 1.0 Orifice coefficient for leakage

PE 1.0E-4 Ambient pressure

RO 1.0E-9 Ambient density

GC 1.0 Gravitational conversion constant

8. Click return twice to close the card image and then close the panel.

Step 5: Define an initial velocity of 3 mm/ms in the negative x-direction for the head with *INITIAL_VELOCITY_GENERATION1. Click BCs > Initial Velocity > Node set > Create.2. For Name:, type velocity and click Create/edit to edit the card image.

3. Under Option, switch the toggle to Generation.4. Under STYP, switch the toggle to select Part ID for the set type.5. Click the PID button twice to select the Head component.6. For velocity in the X direction VX field, specify –3.7. Click return to exit the panel.

Steps 6-12: Define a contact between the airbag and head

Step 6: Create a group with the card image SurfaceToSurface

The following steps explain contact creation using the menu bar.1. Click BCs > Contact > Surf to Surf > Create.2. For Name: type Airbag_Head and click Create to create the card.

Step 7: Specify the head to be the master surface with surface type 3, part ID1. Select the add subpanel.2. Set the master surface type to comps.3. Click comps and select the Head component.4. Click update for the master selection.5. Stay in the add subpanel for the next step.

Step 8: Specify all of the airbag to be the slave surface with surface type 2, part set ID1. Set the slave surface type to sets.2. Click sets and select the pre-defined entity set airbag_set.

This set contains the AirbagFront and AirbagRear components.3. Click update in the slave line to update the slave selection.4. Stay in the add subpanel for the next step.

Step 9: View the master and slave entities and set the option to automatic1. Click review.

2.Notice the master and slave entities are temporarily displayed blue and red, respectively. All other entities are temporarily displayed grey.

3. Click on the Card image subpanel and click edit.4. Set the Option toggle to Automatic.5. Click return to close the panel.

Step 10: Define contact between surfaces of the airbag

The following steps explain contact creation using the Solver Browser.

1.Right click in the Solver Browser and pick Create > *CONTACT > CONTACT (A-O) > *CONTACT_AIRBAG_SINGLE_SURFACE.

2. For Name, type airbag and click OK to create the card.3. Click return to go back to the Interfaces panel.4. Stay in the Interfaces panel for the next step.

Step 11: Define all of the airbag to be the slave surface with slave set type 2, part set ID1. Select the add subpanel.2. Set the slave: surface type to sets.3. Click sets and select the pre-defined entity set airbag_set.4. Click update to update the slave selection.5. Stay in the add subpanel for the next step.

Step 12: View the slave entities1. Click review.

2.Notice the slave entities are temporarily displayed red. All other entities are temporarily displayed grey.


Steps 13- 16: Define a contact between the plate and the airbag with *CONTACT_NODES_TO_SURFACE

Step 13: Create *CONTACT_NODES_TO_SURFACE card1. Click BCs > Contact > Node to Surf > Create.2. For Name:, type Airbag_Plate and click Create to create the card.

Step 14: Specify the AirbagRear_master contactsurf for the contact’s master surface1. Select the add subpanel.2. Set the master surface type to csurfs.3. Click edit to open the Contact Surface panel.4. For name=, type AirbagRear_master.5. For card image =, select setSegment.6. Optionally select a color for the contactsurf.7. With the elems selector active, click elems >> by collector.8. Select the AirbagRear component.9. Click create to create the contactsurf.

Notice the contactsurf’s pyramids point into the airbag. They should point out. In the next step you will reverse their direction.

10. Select the adjust normals subpanel.11. With the contactsurf active, select AirbagRear_master.12. Toggle from by elems to all elems.13. Click reverse normals.14. Click return to exit the panel and return to the Interface panel.15. Click update to update the master selection.16. Stay in the Interfaces panel for the next step.

Step 15: Define the plate to be the contact’s slave surface 1. Set the slave surface type to entity.2. Click nodes and select by collector.3. Select the RigidPlate component.

4. Click add to add the slave selection.5. Stay in the Interfaces panel for the next step.

Step 16: View the master and slave entities1. Click review.

2.Notice the master and slave entities are temporarily displayed blue and red, respectively. All other entities are temporarily displayed grey.

3. Click return to go back to the main menu.

Step 17: Export the model to an LS-DYNA 971 formatted input file

1. Click on Export and select the icon Export Solver Deck . 2. Set Template to Keyword971.

3.Click the Select file icon to select the path and enter the file name as airbag_complete.key.

4. Under Export options, set Export: to All.

5.Click Export.

Step 18 (Optional): Submit the LS-DYNA input file to LS-DYNA 9711. From the Start menu, open the LS-DYNA Manager program.2. From the solvers menu, select Start LS-DYNA analysis.3. Load the file airbag_complete.key. 4. Click OK to start the analysis.


The exercise is complete. Save your work to a .HM file.

CRASH-1300: Rigid Wall, Model Data, Constraints, and Output using DYNA

In this tutorial, you will learn how to:

•Create *PART_INERTIA for the component vehicle mass to partially take into account the inertia properties and mass of the missing parts.

•Create velocity on all nodes but the barrier nodes with *DEFINE_BOX and *INITIAL_VELOCITY.

•Make the closest row of nodes of the crash boxes a part of the vehicle mass rigid body with *CONSTRAINED_EXTRA_NODES.

•Create a contact between the crash boxes, the bumper and the barrier with *CONTACT_AUTOMATIC_GENERAL.

•Specify the output of resultant forces for a plane on the left interior and exterior crash boxes with *DATABASE_CROSS_SECTION_PLANE.

•Create a stationary rigid wall to constrain further movement of the barrier after impact with *RIGIDWALL_PLANAR_FINITE.

•Specify some nodes to be output to the ASCII NODOUT file with *DATABASE_HISTORY_NODE.

*PART_INERTIA

The INERTIA option allows inertial properties and initial conditions to be defined rather than calculated from the finite element mesh. This applies to rigid bodies only.

When importing a DYNA model into Engineering Solutions, the *PART_INERTIA IRCS parameter value is changed from 0 to 1. (The inertia components are changed from global to local axis.) This allows inertia components to be automatically updated when *PART_INERTIA elements are translated or rotated. When selecting *PART_INERTIA elements to translate or rotate, select elements by comp. This selection method ensures the inertia properties are automatically updated.

*CONSTRAINED_EXTRA_NODES

This card defines extra nodes to be part of a rigid body.

*DATABASE_CROSS_SECTION_(Option)

*DATABASE_CROSS_SECTION_(Option) defines a cross section for resultant forces written to the ASCII SECFORC file. The options are PLANE and SET.

For the PLANE option, a cutting plane must be defined. For best results, the plane should cleanly pass through the middle of the elements, distributing them equally on either side.

The SET option requires the equivalent of the automatically generated input via the cutting plane to be identified manually and defined in sets. All nodes in the cross-section and their related elements contributing to the cross-sectional force resultants should be defined in sets.

*DATABASE_CROSS_SECTION_SET and *DATABASE_CROSS_SECTION_PLANE are created from the Solver Browser. Like the Interfaces panel, anything created from the Rigid Walls panel is a HyperMesh group. Thus, to rename, renumber or delete a *DATABASE_CROSS_SECTION card, select groups from the Rename, Renumber or Delete panel.

*RIGIDWALL

A *RIGIDWALL provides a method for treating contact between a rigid surface and nodal points of a deformable body.

Exercise: Set Up the Bumper Model for Impact AnalysisThis exercise will help you become familiar with defining LS-DYNA rigid walls using Engineering Solutions, Crash - LsDyna user profile. It will also help you continue to learn how to define LS-DYNA model data, constraints, and output.

In this exercise, you will define model data, loads, constraints, a rigid wall, and output for an LS-DYNA analysis of a bumper in a 40% frontal offset crash. The bumper model is shown in the image below.

Bumper model

Step 1: Load the LS-DYNA user profile1. Engineering Solutions > Crash - HyperMesh.2. Select LsDyna.

Step 2: Import the LS-DYNA model bumper_start.key1. Click File > Import > Solver Deck. 2. In the File: field, browse to the file bumper_start.key.3. Click Import.

Step 3: Define *PART_INERTIA for the vehicle mass component to partially take into account the inertia properties and mass of the missing parts

1. Right click on vehicle mass in the Model Browser and click Card Edit.2. Click the switch under Options and select Inertia. 3. For the center of mass coordinates XC enter 700.4. In the YC field, enter 0.5. In the ZC field, enter 170. 6. For translational mass TM, specify 800.

7. For the components of the inertia tensor, specify the following:

IXX IXY IXZ IYY IYZ IZZ

1.5E+07 -5.0E+03 -8.0E+06 5.0E+07 -900

6.0E+07

8. For the initial translational velocity along the X-axis, VTX, specify -10.9. Click return to exit the panel.

Step 4: Create a box that contains all nodes but the barrier nodes1. Click Model > Box > Create .2. In the name= field, type box velocity.3. Optionally select a color.4. Toggle lower bound from corner node to x=, y=, z=.5. Specify the lower and upper bounds as follows:

lower bound upper bound

X= -530 200

Y= -800 800

Z= 0 300

6. Click create to create the box.7. Click return to close the panel.

Step 5: Create initial velocity on all nodes but the barrier nodes1. Click BCs > Initial Velocity > Node Set > Create.2. For Name, type velocity and click Create/edit to create the card.3. For the initial velocity in the global X direction, VX, specify –10.4. Click on the BOXID field and select the box velocity created in Step 4. 5. Click return to close the panel.

Note:

You can also create velocity boundary condition on a set of

nodes by clicking the load collector icon in the tool bar and picking Initialvel as the card image.

Step 6: Review the closest nodes which are in the pre-defined node set named Constrain Vehicle1. In the Solver Browser, right-click on Constrain Vehicle and select Review.

Notice the set’s nodes are highlighted.

2.Right click on Constrain Vehicle again and select Reset review to return to normal display mode.

Step 7: Create *CONSTRAINED_EXTRA_NODES_SET1. Click Connections > Extra node > Create.2. In the Name field, enter ExtraNodes. 3. Click Create/edit to create the card and open the card image panel.

4.

Click the part id (PID) field to activate it, and then select it again. Select the vehicle mass component. This is the rigid body to which the nodes will be added. The ID is automatically entered into the card.

5. Click return to go back to the Interfaces panel.

Stay in the Interfaces panel for the next step.

Step 8: Define the nodes in the Constrain Vehicle set to be a part of the vehicle mass rigid body1. Select the add subpanel.2. Make sure name= is set to ExtraNodes.3. Set the slave type to sets.4. Click on sets and select the Constrain Vehicle set.5. Click select.6. Click update to update the slave selection. 7. Stay in the Interfaces panel for the next step.

Note:

You can also create an extra node set on a set of nodes in the Solver Browser by right clicking and selecting Create > Constrained_Extra_node.

Step 9: View the extra nodes that are a part of the vehicle mass rigid body1. Click review.

Notice the extra nodes are temporarily displayed red while the PID (vehicle mass) is temporarily displayed blue. All other entities are temporarily displayed grey.


Step 10: Create general contact

1.Click Bcs > Contact > General > Create .

2. For name, type impact.3. Click Create/edit to create the card.

Note:

You can also create *CONTACT_AUTOMATIC_GENERAL by right-clicking in the Solver Browser and selecting Create > *CONTACT (A-O) > AutomaticGeneral.

Step 11: Define the slave parts1. Select the add subpanel.2. Make sure name= is set to impact.3. Set the slave type to sets.

4. Click on edit.

The entity sets panel opens, where you can create the set.

5. For name=, type Exempt Parts.6. Make sure the card image field is set to Part.7. With the comps selector active, select the vehicle mass component.8. Click create to create the set.9. Click return to exit the panel.

Notice you are back in the Interface panel. 10. Click update to update the slave selection.11. Select the card image subpanel.12. Click edit to edit the group.13. Activate the option ExemptSlvPartSet.

14.

Notice the slave surface type SSTYPE value changes from 2 (part set ID) to 6 (part set ID for exempted parts). This implies all entities except the entities in the set are defined as slave for the contact.

15. For the static coefficient, FS, specify 0.15.16. Click return to go back to the Interfaces panel.17. Click return to exit the panel.

Step 12: Define a section by creating *DATABASE_CROSS_SECTION_PLANE1. Click Output > Section > Create.2. In the Name field, type Xsection_Plane.3. Click Create to create the part.4. Stay in the same panel for the next step.

Note:

You can also create *DATABASE_CROSS_SECTION_PLANE from the Solver Browser by right-clicking and selecting Create > *DATABASE_CROSS_SECTION_PLANE.

Step 13: Define the location and size of the section’s plane

In this sub-panel, the plane’s origin (the tail of the normal vector) is defined by a base node. Create a node from the create nodes panel by following steps 1 - 4 below and then select it for the base node.1. Press the F8 key to enter the Create Nodes panel.

2. Select the XYZ subpanel.3. For x=, y= and z=, enter the values –320, -500 and 100, respectively.4. Click create to create the node.

Notice the node is created and is displayed.5. Click return to go back to the geom subpanel of the Rigid Walls panel. 6. With the base node selector active, graphically select the node just created.7. Switch normal vector to x-axis.

This defines the wall’s normal vector.8. Leave shape set to plane.9. Toggle from infinite to finite.10. Toggle from corners to dist/axis.11. Switch local x axis: to y-axis.

This defines the edge vector L.

12. For len x= and len y=, specify 100 and 200, respectively.

Doing this defines the extent of the section. The values are the length of the edges a and b in the L and M directions, respectively.

13. Click update to update the group.14. Stay in the same panel for the next step.

Step 14: Specify the parts for the selection1. Select the add subpanel.2. Set the slave type to comps.

3.With the comps selector active, select the components interior crashbox and exterior crashbox

4. Click update to update the slave selection.5. Stay in the same panel for the next step.

Note:

During export, a set is created from the selected comps and is attached to the section definition in its card image.

Step 15: View the entities

1.Click review. Notice the slave entities are displayed red while the section wall is displayed blue. All other entities are temporarily displayed grey.


Step 16: Create a box containing the nodes making up the barrier and bumper’s left side

These nodes will be slave to the rigid wall. 1. Click Model > Box > Create.2. In the name= field, type half model.3. Optionally select a color.4. Specify the lower and upper bounds as follows:


X= -600 -460

Y= -800 0

Z= 0 400

5. Click create to create the box.6. Click return to close the panel.

Step 17: Define a planar rigid wall1. Click BCs > Rigid wall > Planar > Create. 2. In the Name field, type wall.3. Click Create. 4. Stay in the Rigid Walls panel for the next step.

Note: You can also create *RIGIDWALL_PLANAR_FINITE by right-clicking in the Solver Browser and selecting Create > *RIGIDWALL_PLANAR_FINITE.

Step 18: Define the location and size of the rigid wall

In this sub-panel, the rigid wall’s origin (the tail of the normal vector) is defined by a base node. Create a node from the create nodes panel by following steps 1-4 below and then select it for the base node. 1. Make sure name=, is set to wall.2. Press the F8 key to enter the Create Nodes panel.

3. Select the XYZ subpanel.4. For x=, y= and z=, enter the values –600, -750 and 90, respectively.5. Click create. Notice the node is created and is displayed.6. Click return to go back to the Rigid Walls panel, geom subpanel. 7. With the base node selector active, select the node that was created in step 4.8. Switch normal vector: set to x-axis.9. Leave shape: set to plane.10. Toggle from infinite to finite.11. Toggle from corners to dist/axis. 12. Select y-axis for local x axis.13. For len x= and len y=, specify 615 and 250, respectively.

These values define the extent of the wall. They are the length of the edges l and m, respectively.

14. Click update to update the group.15. Stay in the Rigid Walls panel for the next step.

Step 19: Edit the card image for the rigid wall to specify the nodes in the *DEFINE_BOX half model as slave to the rigid wall1. Select the card subpanel.2. Click edit to edit the group. 3. Click the BOXID field twice and select the box half model.4. In the field FRIC, specify 1.0 for the friction coefficient.5. Click return to go back to the Rigid Walls panel.6. Click return to close the panel.

Step 20: Specify some nodes to study during post-processing 1. Click Output > Node > Create.2. In the name field, type nodeth.3. Set the entity selector to nodes.4. Select a few nodes of interest from the graphics area.5. Click create to create the output block.6. Click return to close the panel.

Step 21: Export the model to an LS-DYNA 971 formatted input file1. Click File > Export > Solver Deck to open the Export tab.2. Make sure the File Type: field is set to LsDyna.3. Save the file as Bumper_complete.key.4. Click Export.

Step 22 (Optional): Submit the LS-DYNA input file to LS-DYNA 9711. From the Start menu, open the LS-DYNA Manager program.

2. From the solvers menu, select Start LS-DYNA analysis.3. Load the file bumper_complete.key. 4. Click OK to start the analysis.


The exercise is complete. Save your work to a .HM file.

CRASH-2000: Front Impact Bumper Model

For this tutorial it is recommended to complete the introductory tutorial Pre-Processing for Pipes Impact Using RADIOSS Block - RD-3520 for basic concepts on the Engineering Solutions RADIOSS interface.

In this tutorial you will learn how to set up a RADIOSS input deck for analysis of the impact of a bumper against a barrier behind a rigidwall. The modeling steps that are covered are:• Associating /PART, with /MAT and /PROP

•Converting node-to-node connections (/RBODY) into a mesh-less welding formulation (/INTER/TYPE2 with /SPRING) using connectors

• Defining the contact for the elements in the bumper with an /INTER/TYPE7 card• Defining the interaction between bumper and barrier with an /INTER/TYPE7 card

•Defining the interaction between barrier and rigid wall with the /RWALL/PLANE and /BOX cards

•Specify the output of resultant forces for a plane on the left interior and exterior crash boxes with /SECT

• Creating a /TH/NODE card to output time history for nodes

The units used in the model are millisecond, millimeter and kilogram (ms, mm, kg), and the tutorial is based on RADIOSS Block 100

Exercise: The model used consists of a simplified bumper model (see image below):

Bumper model

Step 1: Load the Engineering solutions - RADIOSS (BLOCK) user profile1. Launch Engineering solutions > Crash (HyperMesh) from the Start menu.

2. Alternatively, you click Preferences > User Profiles or click on the icon in tool bar .3. Select Crash and Radioss and click OK.

Step 2: Load the model file

1.From the toolbar, click the Open Model icon and browse to select the bumper.hm file from the directory <install_directory>\tutorials\es\crash. Click Open.


Step 3: Define vehicle mass component to partially take into account the inertia properties and mass of the missing parts of the vehicle1. Right click in the Model Browser and select Create > Component.2. For Name, enter Vehicle mass and click Create. 3. Click Geometry > Create > Nodes > XYZ. 4. In the X field enter 700.5. In the Y field, enter 0.6. In the Z field, enter 170. 7. Click create to create the node.8. Click return to exit the panel.9. Click Connections > Rigid Body > Create.10. Click the selector arrow next to the nodes 2-n: button and choose sets.

11.Click the yellow nodes button next to primary node and select the node created in step seven above.

12. Click on sets and select the Constrain Vehicle set.13. With all the DOF’s checked, click create to create the rigid body.

Note: A spider will be drawn connecting the created node to the edge nodes of the structure modeled.

14.Click on the card edit icon in the tool bar, set the selector to elems and select the rigid body created. Click edit.

15. Fill the mass and inertia information in the card image as in the table below:

Mass J_XX J_XY J_XZ J_YY J_YZ J_ZZ

800 1.5E+07 - -8.0E+06 5.0E+07 -900 6.0E+07

5.0E+03

16.Set ICOG as 4, and ISPHER as 0.

17. Click return until you close all the open panels.

Step 4: Create a node set using a box that contains all nodes but the barrier nodes1. Click Model > Box > Node > Create.2. In the name= field, enter box velocity.3. Optionally select a color.4. Toggle lower bound from corner node to x=, y=, z=.5. Specify the lower and upper bounds as follows:


X= -530 710

Y= -800 800

Z= 0 300

6. Click create to create the box.7. Click return to exit the panel.

Step 5: Create initial velocity on bumper but the barrier 1. Click BCs > Initial Velocity > Translation.2. In the BCs Manager, enter the name as tran_vel.3. Set the entity selector to GRNOD (BOX).4. Click GRNOD (BOX) and pick box velocity.

5.In the BCs Manager, enter the initial velocity components as -10, 0 and 0 for Vx, Vy and Vz fields.

6. Click the Create button.7. Click Close to close the BCs Manager tab.

Step 6: Define master surface for contact1. Open the Solver Browser by clicking View > Solver Browser.2. Right click in the Solver Browser and pick Create > SURF_EXT > PART.3. For name:, type barrier_surface.4. Click on comps and select barrier.5. Click select.6. Click create.7. Right click in the Solver Browser and pick Create > SURF > PART.

8. For name:, type bumper_surface.

9.Click on comps and select bumper, exterior crashbox left, exterior crashbox right, interior crashbox left, and interior crashbox right.

10. Click select.11. Click create.12. Right click in the Solver Browser and pick Create > SURF > SURF.13. For name:, type barrier_bumper_surface. 14. Click on sets and select barrier_surface, and bumper_surface.15. Click select.

16.Click create.

17. Click return to close the panels.

Step 7: Create self impact contact between parts of the bumper1. Click BCs > Contact > General > Create.2. For name:, type impact. 3. Click create to create the card.4. Select the add subpanel.5. Make sure name= is set to impact.6. Set the slave type to comps and select bumper, interior crashbox and exterior crashbox.7. Click update to update the slave selection.8. Set the master type to sets and select barrier_bumper_surface.9. Click update to update the master selection.

10. Click the card edit icon 11. Click groups and select the group impact.12. Click edit to edit the group.13. For the static coefficient, FRIC, specify 0.15.14. Set Igap = 2.15. Click return until you exit all the open panels.

Step 8: Create a system that specifies the location and the cross section plane normal

1. Click on the Display Numbers icon in the toolbar. 2. Click on the node selector and choose by ID.3. For the ID’s enter 6227, 6224, 5993. 4. Check the display check box on.5. Click On.

Note: Node numbers will appear next to the node for selection in further steps6. Click return.7. Click Model > Systems > Frame_Move > Create.8. Select node ID 6224 for origin node.9. Select node ID 6227 for Z axis.10. Select node ID 5993 for YZ plane.11. Click create to create a system.

12. Click the card edit icon on the toolbar.13. Set the entity selector to systs.14. Pick the system and click edit.15. Change the option from Skew to Frame.16. Click return until you exit all the open panels.

Step 9: Create a set of elements that will contribute to the cross-sectional force results1. Click Model > Sets > Shell-4 > Create.2. In the name= field, type XsectionPlane-elements.

3.With the elements selector active, select two rows of element on either side of the system as shown in figure below.

4. Click create to create the set.5. Click return to exit the panel.

Step 10: Define a section 1. Right click in the Solver Browser and pick Create > SECT.2. In the Name field, type Xsection_Plane. 3. Click OK to create the card.4. Click on the Normal vector drop down and pick systemid.5. Select the system defined in the previous step by clicking on the screen.6. Click update to update the plane geometry.7. Click on the add subpanel.

8.Change the slaves: entity selector to sets. Click the yellow sets button and select XsectionPlane-elements.

9. Click update to update the SET. 10. Click return to exit the panel.

Step 11: Select the section for time history output1. Click Output > Section > Create.

2. Enter Section_force as the name.3. Click on groups and pick Xsection_Plane.4. Click create. 5. Click edit to go to the card image.6. Change the option from INTER to SECTION.7. Click return twice to close the panels.

Step 12: Create a node set using box containing the nodes making up the barrier and bumper’s left side

These nodes will be slave to the rigid wall. 1. Click Model > Box > Node > Create.2. In the name= field, type half model.3. Optionally select a color.4. Specify the lower and upper bounds as follows:


X= -600 -460

Y= -800 0

Z= 0 400

5. Click create to create the box.6. Click return to exit the panel.

Step 13: Define a rigid wall 1. Click BCs > Rigid Wall > Create.2. In the name: field, type wall.3. Click create.

Stay in the Rigid Walls panel for the next step.

Step 14: Define the location and size of the rigid wall

In this subpanel, the rigid wall’s origin (the tail of the normal vector) is defined by a base node. Create a node from the create nodes panel by following steps 1-4 below and then select it for the base node. 1. Press the F8 key to enter the create nodes panel.

2. Select the XYZ subpanel by clicking the icon .3. For x=, y= and z=, enter the values –600, -750 and 90, respectively.4. Click create.

Notice the node is created and is displayed.5. Click return to go back to the rigid walls panel, geom subpanel. 6. With the base node selector active, select the node that was created in step 5.7. Switch normal vector to x-axis.8. Leave shape: set to infinite plane.9. Click update to update the group.

Stay in the Rigid Walls panel for the next step.

Step 15: Edit the card image for the rigid wall to specify the nodes in the GRNOD/BOX half model as slave to the rigid wall1. Select the add subpanel.2. Set the slaves: entity selector to rad_box.3. Select the Card page and click edit to edit the rigid wall definition. 4. In the Grnod1BOX field, specify the ID of the box half model.5. In the field FRIC, specify 1.0 for the friction coefficient.6. Click return to go back to the Rigid Walls panel.7. Click return to exit the panel.

Step 16. Initialize sheet metal components with stamping data

1. Click on the Results Initializer Icon .

2.The Create / Open Process Instance dialog comes up as shown below. In the dialog select the folder where you will finally export the model in the Folder field.

3. Click on Create/ Open.

4.The Process Manager is displayed in the browser tab area, and the panel opens the Process Manager, as shown below.

5.Click on Add, followed by Comps and pick the components exterior crashbox left, exterior crashbox right, interior crashbox left, and interior crashbox right.

6. Click on the Next button.7. Change the Blank holder force to low for all the components.8. Click on Initialize.

The Initialization process starts. This process takes few minutes. During this time HM session is unavailable for editing.

9. Select % thinning for Result Type and All for Components. 10. Click on Review. The components will be contoured with thinning coming from stamping. 11. Click return to come back to the results selection.

12.Similarly repeat the same series of steps for plastic strain to review initial hardening in the component.

13. Click on Next until all stages are complete in the Process Manager.14. Click on Close to close the Results Initializer.

Note: The results are attached to the model as include files. These include files are in the same directory as selected in step 2.

Step 17: Create output requests and control cards 1. Click Output > Engine file.

The Radioss Engine File Tool window appears.2. Enter the values as shown below:

3. Click on the ANIM tab and fill in the options as shown below:

4. Click on the DT tab and fill in the options as shown below:

5. Click Apply and then click Close.

Step 18: Export the model

1. Click the Export icon .2. For File:, click the folder icon and navigate to destination directory where you want to run.3. Enter the name as bumper_impact and click Save.4. Click the downward-pointing arrows next to Export options to expand the panel.5. Click Auto export engine file to export the engine file with the model file.6. Click on Export to export both model and engine file.

Step 19: Run the solver using RADIOSS Manager 1. Go to Start > Programs > Altair HyperWorks 11.0 > RADIOSS.2. For Input file, browse to the exercise folder and select the file bumper_impact_0000.rad.

Step 21: Model setup without results initialize1. Repeat the same process from Step 1 to step 19 except step 16.2. Save the model as bumper_impact_noresult.

Step 22: Postprocessing in HyperGraph1. Open HyperGraph from the Startup menu.

2.Click the file open icon and load the model bumper_impactT01 file from the folder where the model was saved in step 18.

3.Select Section for Type, Sect. for Request and FNZ for component. Click Apply to plot the curve.

The curve describes the force carried by the section defined in step 10 during frontal impact.

4.Click the file open icon and load the model bumper_impact_noresultsT01 file from the folder where the model was saved in step 18.

5.Select Section for Type, Sect. for Request and FNZ for component. Click Apply to plot the curve.

Absorb Curve 1 is above Curve 2 indicating the higher load carrying capacity of the components when stamping prestrains are included as in physical impact tests.

CRASH-2100: Simplified Car Pole Impact

The goal of this tutorial is to simulate a frontal pole test with a simplified full car.

Model Description

• UNITS: Length (mm), Time (s), Mass (ton), Force (N) and Stress (MPa)• Simulation time: Engine [0 – 0.06]

•An initial velocity of 15600 mm/s is applied on the car model to impact a rigid pole of radius 250 mm.

• Elasto-plastic Material /MAT/LAW2 (Windshield)

Initial Density [Rho_I] = 2.5x10-9 ton/mm3

Young's Modulus [E] E = 76000 MPa

Poisson’s Ratio [nu] = 0.3

Yield Stress (a) 0 = 192 MPa

Hardening Parameter (b) K = 200 MPa

Hardening Exponent (n) n = 0.32

•Elasto-plastic Material /MAT/LAW2 (STEEL)

Initial Density [Rho_I] = 7.9x10-9 ton/mm3



Yield Stress (a) 0 = 200 MPa

Hardening Parameter (b) K = 450 MPa

Hardening Exponent (n) n = 0.5

Maximum Stress [SIG_max] max = 425 MPa

•Elasto-plastic Material /MAT/LAW2 (RUBBER)

Initial Density [Rho_I] = 2x10-9 ton/mm3



Yield Stress (a) 0 = 1e30 MPa

Hardening Exponent (n) n = 1

Exercise

Step 1: Load the Engineering Solutions Radioss user profile1. Launch Engineering solutions > Crash (HyperMesh) from the Start menu.

2. Alternatively, you click Preferences > User Profiles or click on the icon in the toolbar .3. Select Crash and Radioss and click OK.

Step 2: Load the model file

1.From the toolbar, click the Open .hm file icon and browse to select the model file fullcar.hm file.

2. Click Open.


Step 3: Create and assign the material for the windshield components1. In the Model Browser, right-click and select Create > Material. 2. In the Name field, enter windshield.3. Set the Type field to ELASTO-PLASTIC. 4. Choose M2_PLAS_JOHNS_ZERIL for Card image.5. Activate the checkbox Card edit material upon creation.6. Click Create. The card image panel appears.7. Enter the values as shown in the card image below:

8. Click return.9. Right-click on COMP-PSHELL3 and select Edit.

The Edit component dialog opens. 10. Click on the Material tab.11. Check the Assign material box.12. In the Name field, select windshield.

13. Click Update to update the selected components with the created material.14. Repeat steps 9 - 14 for component COMP-PSHELL16.

Step 4: Create and assign the material for 1D components

1.In the Model Browser select all components from COMP_PROD8 to COMP_PROD14 and choose Edit from the context sensitive menu.

A new dialog appears.2. Go to the Materials tab.3. Check the Assign material.4. For name, enter steel, 5. Set the Type field to ELASTO-PLASTIC. 6. Choose M2_PLAS_JOHNS_ZERIL for card image.

7. Click Create material. The card image panel opens.8. Enter the following values:

Rho_Initial 7.900e-09

E 210000.00

nu 0.300

a 200.000

b 450.000

n 0.500

SG_max 425.000

9. Click return.10. Click update to update the selected components with the created material.

Step 5: Assign material steel for other 2D components

1.

In the Model Browser, select all components from COMP_PSHELL_1 to COMP_PSHELL_30 except COMP_PSHELL3, COMP_PSHELL16 and COMP_PSHELL20 to COMP_PSHELL23, COMP-PSOLID_24 – COMP-PSOLID_26 and choose Assign from the context sensitive menu

2. For the material, select Steel3. Click on assign to assign the steel material to the selected components.

Step 6: Create and assign the material for the rubber components

1.In the Model Browser select COMP-PSHELL20 to COMP-PSHELL23 and choose Edit from the context sensitive menu.

A new dialog pops up.2. Go to the Materials tab.3. Check Assign material.4. For name, enter rubber, 5. Set the Type field to ELASTO-PLASTIC. 6. Choose M2_PLAS_JOHNS_ZERIL for the Card image field.7. Click Create material. The card image panel appears as shown in the image below.8. Enter the values as shown in the card image below:

9. Click return to exit the panel.10. Click update to update the selected components with the created material.

Step 7: Create a Rigid Wall1. Click BCs > Rigid Wall > Create.2. For name, enter Ground and click Create.3. Go to the geom subpanel.4. For shape, select infinite plane.5. Click on base node and select any node from the model.6. Click the edit button and input X = 0, Y = 0, and Z = -1.7. Click return.8. Toggle the switch under normal vector and select components.

9. In the Z comp field, define the normal vector Z= 1.10. Click update.11. Go to the add subpanel. In the dist field, enter 200 for slave nodes search.12. Click update and then click return.

Step 8: Create a Cylindrical Rigid Wall to represent pole1. Click BCs > Rigid Wall > Create.2. Enter RW as the name and click create.3. Go to the geom subpanel.4. For shape, select cylinder.5. Click on base node and select any node from the model.6. Click the edit button and input X = -320, Y = 1250 and Z = 0.7. Click return.8. In the radius = field, enter 250. In the length = field, enter 500.9. Under normal vector, in the Z comp field, define the normal vector Z= -1.10. Click update.11. Go to the add subpanel. In the dist field, enter 1500 for slave nodes search.12. Click update and then click return.

Step 9: Defining Self Contact between the parts of the vehicle1. Click BCs > Contact > General > Create.2. Make sure you are in the create subpanel. For name =, enter CAR_CAR.3. Select a color and click create.4. Go to the add subpanel to define the master and slave.5. For the master surface, click the switch to comps.

6.Hide all the 1D and 3D parts in the model using Mask Browser, Model Browser property view, or Solver Browser and isolating PROP > SHELL.

7. Click on comps >> displayed.8. For slave nodes, select comps in the drop down menu.9. Click on comps >> all in the model.10. Click review to graphically view the entities in the interface.

The master entities of the interface are drawn in blue and the slave entities in red.11. Go to the card image subpanel and click edit.12. Enter FRIC as 0.200 and GAPmin as 0.7.13. Click return to close the panel.

Step 10: Defining Contact between Engine and Radiator1. Click BCs > Contact > General > Create.2. Enter the name= as ENGINE_RADIATOR.3. Optionally select a color and click create.4. Go to the add subpanel to define the master.5. For the master surface, click the switch to sets and click edit to go to the Entity Sets panel.6. For name, enter engine and set the card image to SURF_EXT.7. Set the entity selector to comps and select comp-psolid_24 (engine).8. Click create to create the set.9. Click return to go back to the Interface panel.10. Click update to update the master selection.

11. For slave, set the entity selector to comps and select comp-psolid_26 (radiator).12. Click update to update the slave selection.

13. Go to the card image subpanel and click edit.14. Input the values, as shown below.

15. Click return to exit the panel.

Step 11: Defining initial velocity1. From the Utility Menu, start the BCs Manager.

2.For Name, enter 35MPH, set the Select type field to Initial Velocity and set GRNOD to Parts.

3. Click on the parts and select all in the model.4. Set Vx as 15600.

5. Click Create to create the boundary condition and boundary condition appears in the table.

Step 12: Create Time History Nodes

1.Using either the Model Browser, or the Solver Browser and a virtual collector, isolate the rail parts (PCOMP-SHELL19) in the graphics area.

2. Click Output > Node > Create.3. For name =, enter Rail and select nodes on the rail, as shown below.

4. Click create, followed by edit.5. In the Var: field, enter DEF.6. Click return to close the panel.

Step 13: Allocate Required Memory1. From the Model menu, select Control cards 2. Click on MemoryReq.3. Input NMOTS as 75000.4. Click return.

Step 14: Create output requests1. From the Output menu, click Engine File.

The Radioss Engine File Tool window appears.2. In the GENERAL tab, enter the values, as shown in the following image.

3. Click Apply.4. In the ANIM tab, enter values as shown in the following image:

5.Click Apply and then click Close.

Step 15: Export the model

1. From the toolbar, click the Export icon .2. For File:, click the folder icon and navigate to destination directory where you want to run.3. Enter the name as fullcar and click Save.4. Click the arrows next to Export options to expand the panel.5. Click Auto export engine file to export the engine file with the model file.

6. Click on Export to export both model and engine file.

Step 16: Run the solver using RADIOSS Manager 1. Click Start > Programs > Altair HyperWorks 11.0 > Radioss.2. For Input file, browse to the exercise folder and select the file fullcar_0000.rad.

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