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HyperCrash Introduction
Pre-Processing for RADIOSS Crash Analysis

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Trademark and Registered Trademark Acknowledgments


Listed below are Altair HyperWorks applications. Copyright Altair Engineering Inc., All Rights Reserved for: HyperMesh 1990-2009; HyperView 1999-2009; OptiStruct 1996-2009; RADIOSS 1986-2009; HyperCrash 2001-2009; HyperStudy 1999-2009; HyperGraph 1995-2009; MotionView 1993-2009; MotionSolve 2002 2009; TextView 1996-2009; MediaView 1999-2009; HyperForm 1998-2009; HyperXtrude 1999-2009; HyperView Player 2001-2009; Process Manager 2003-2009; Data Manager 2005-2009; Assembler 2005-2009; FEModel 2004-2009; BatchMesher 2003-2009; Templex 1990-2009; Manufacturing Solutions 2005-2009; HyperDieDynamics 2007-2009; HyperMath 2007-2009; ScriptView 2007-2009. In addition to HyperWorks trademarks noted above, GridWorks, PBS Gridworks, PBS Professional, PBS and Portable Batch System are trademarks of ALTAIR ENGINEERING INC., as is patent # 6,859,792. All are protected under U.S. and international laws and treaties. All other marks are the property of their respective owners.

HyperCrash Introduction I

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HyperWorks 10.0

Table of Contents

HyperCrash Introduction
Pre-processing for RADIOSS Crash Analysis

Chapter 1: Getting Started ..................................................................................... 1


Section 1: Windows Description........................................................................................ 1 Section 2: Mouse Modes................................................................................................... 2 Section 3: Keyboard Options ............................................................................................ 3 Section 4: Display Toolbar ................................................................................................ 4 Section 5: Info Toolbar ...................................................................................................... 8 Section 6: Tree Window .................................................................................................... 9 Section 7: Help In HyperCrash.......................................................................................... 9 Section 8: Description of the Example .............................................................................. 9

Chapter 2: Introduction ........................................................................................ 11


Section 1: Open HyperCrash and Read the Input File .................................................... 11 Section 2: Tree Structure Hierarchy ................................................................................ 14 Section 3: Delete a Part .................................................................................................. 18 Section 4: Mesh Class Definition .................................................................................... 18

Chapter 3: Material and Property Allocation ...................................................... 21


Section 1: Create Material............................................................................................... 21 Section 2: Modify Materials ............................................................................................. 23 Section 3: Material Allocation.......................................................................................... 25 Section 4: Create Properties ........................................................................................... 27 Section 5: Modify Properties ........................................................................................... 29

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HyperCrash Introduction II

Section 6: Property Allocation ......................................................................................... 30 Section 7: Mat & Prop Allocation from the Tree Window ................................................ 32

Chapter 4: Element Creation/Modification .......................................................... 39


Section 1: Create New Elements .................................................................................... 39 Section 2: Modify Elements............................................................................................. 42 Section 3: Split a Part into Two Parts.............................................................................. 44 Section 4: Create a Reinforcement ................................................................................. 45 Section 5: Create a Symmetry of a Part.......................................................................... 47

Chapter 5: Connections........................................................................................ 49
Section 1: Read a Spotfile file (MWF Format)................................................................. 49 Section 2: Display Spotweld Options .............................................................................. 52 Section 3: Spotweld Checking ........................................................................................ 54 Section 4: Create New Spotwelds................................................................................... 57 Section 5: Export a New Spotweld File ........................................................................... 58 Section 6: Bolt Creation .................................................................................................. 59 Section 7: Tied Interface Creation................................................................................... 63 Section 8: Check the Model Connections ....................................................................... 65

Chapter 6: Merge and Connect the Subsystems ................................................ 67


Section 1: Read the Engine File...................................................................................... 67 Section 2: Connect the Engine and the Transmission .................................................... 70 Section 3: Check the Mass Balance of the Model........................................................... 74 Section 4: Merge the Barrier ........................................................................................... 77 Section 5: Move the Barrier to its Correct Location......................................................... 78

Chapter 7: RADIOSS Features ............................................................................. 81


Section 1: Create a Boundary Condition......................................................................... 81 Section 2: Create an Interface to Handle the Contacts for the Car................................. 83 Section 3: Create an Interface to Handle the Contects Between the Car and Barrier .... 85 Section 4: Create an Initial Velocity to Apply to the Entire Car ....................................... 86 Section 5: Create an Added Mass on the Right Door ..................................................... 88 Section 6: Create a Rigid Wall to Model the Ground ...................................................... 91

Chapter 8: Quality Check...................................................................................... 93


Section 1: Check the Intersections and Penetrations in the Model................................. 93 Section 2: Check the Thicknesses .................................................................................. 87

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Section 3: Check the Model with ModelChecker............................................................. 87

Chapter 9: Replace Function ............................................................................. 103 Chapter 10: Time History Selection................................................................... 107
Section 1: TH Node Selection ....................................................................................... 107 Section 2: TH Section Creation ..................................................................................... 108 Section 3: TH Part Creation .......................................................................................... 110

Chapter 11: Clean the Model.............................................................................. 113 Chapter 12: Final Steps ...................................................................................... 115
Section 1: Export the Model .......................................................................................... 115 Section 2: Run the Starter for this Model ...................................................................... 118

Chapter 13: Dummy Positioner.......................................................................... 121


Section 1: Load the Dummy .......................................................................................... 121 Section 2: Position the Dummy ..................................................................................... 124

Chapter 14: Seatbelt Generator ......................................................................... 127 Appendix 1: The M00 File, a HyperCrash file ................................................... 131

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HyperCrash Introduction IV

HyperCrash Introduction V

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HyperWorks 10.0

Chapter 1: Getting Started

Chapter 1

Getting Started
Section 1: Windows Description
The HyperCrash environment window is composed of the following menus and windows: The Notebook Window, located on the left side of the HyperCrash environment window The Graphic Window, located in the center of the HyperCrash environment window The Message Window, located below the Notebook Window The Pull-down Menu Bar, located across the top of the HyperCrash environment window The Display Toolbar, located on the right side of the environment window The Info Toolbar, located on the lower right corner The Dialog Menu Bar, located at the bottom of the HyperCrash environment window The Tree Toolbar located at the top of the Tree Window.

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HyperCrash Introduction 1

Chapter 1: Getting Started

Section 2: Mouse Modes


Two mouse settings are now available: the classic HyperCrash mode and a new one that follows the HyperMesh\HyperWorks approach. You can now switch from one mode to another while in an active session (select the Options menu and activate or deactivate Use Classic Mouse Setting). Classic HyperCrash Mouse Mode Task Description Middle + right mouse button: Rotations Press the C key and pick a node with the left mouse button to change the center of rotation. Press the CTRL and C keys to switch off the automatic center of rotation. Press the SHIFT and C keys to switch on the automatic center of rotation. Translations Right mouse button: Zoom Zoom in: middle mouse button and slide up: Zoom out: middle mouse button and slide down. Zoom box in: press the Z key and drag a box in the graphic window with the left mouse button: Zoom box out: press the SHIFT and Z keys and drag a box in the

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Chapter 1: Getting Started

graphic window with the left mouse button. Zoom in: press the key. Zoom out: press the key. HyperMesh/HyperWorks Mouse Mode Task Description Rotations Press the CTRL key + left mouse button and move the mouse around. The model rotates with the movement of the mouse. Release the left mouse button and press it again to rotate the model in a different direction. Press the CTRL key and quick-click the left mouse button anywhere on the model to pick a new center of rotation. Press the CTRL key + left mouse button to rotate the model on this new center of rotation. Translations Press the CTRL key + right mouse button and move the mouse around. The model is panned (translated) according to the mouse movement. Zoom Press the CTRL key + middle mouse button, move the mouse around, and then release the mouse button. A white box is drawn according to the area of the mouse movement. When the mouse button is released, HyperCrash zooms in on the portion of the model where the box was drawn. Press the CTRL key + quick-click the middle mouse button. The model is fitted to the graphic window. Press the CTRL key and spin the mouse wheel. The model zooms in or out depending on which direction you spin the mouse wheel.

Section 3: Keyboard Options


F1, F2, F3 and F4: in picking mode, when more than one element is selected, F1 and F2 allow you to switch from one element to another. Then, F3 allows you to validate or F4 allows you to cancel the choice. F5: Display the rigid walls. F6: Display the rigid bodies. F7: Display the initial velocities. F8: Display the free nodes (not belonging to any element). F9 > F12: Standard views (clicking the same key a second time will reverse the view). SHIFT F5: Display the added masses. SHIFT F6: Display the boundary conditions. SHIFT F7: Display the contact interfaces. SHIFT F8: Clear all displayed options. SHIFT C: Switch on the automatic center of rotation. W: Set the background color to white. B: Set the background color to black.

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HyperCrash Introduction 3

Chapter 1: Getting Started

P: Switch between perspective view and orthogonal view. Z: Zoom in (press Z and drag a box with the left mouse button in the Graphic Window). SHIFT Z: Zoom out box. ENTER or Y key: Yes (validate or accept). ESC key: Cancel or dismiss.

Section 4: Display Toolbar


Using the view mode icons of the Display Toolbar, you can access different views of your model. When you are loading your model, all the parts are visible in the Graphic Window, called the Front Screen. To get a better view of the parts you are working on or to help you gain a better understanding of the model, you can remove the selected parts from the Front Screen. The unselected parts are visible in the Graphic Window called the Reverse Screen. This is the HyperCrash Show / No Show system. Refresh graphic window Center the model and fit it to the screen Isolate by element type (shells, trusses, springs, beams, or solids) Mask by element type Display / hide details Display / hide free nodes Display graphic object Control display elements Unmask selected parts Display connected elements Mask selected parts Isolate selected parts Views Display parts connected to selected part Mask boxed parts Isolate boxed parts Display mode View simplification Display by element type Control transparency level Display solid elements / display external solid surfaces Mask all graphic objects Display by tree selection Display parts in node proximity Toggle Reverse Display Display all parts in a model

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Chapter 1: Getting Started

Note: Some good feature for displaying and undisplaying parts: Ctrl + Shift and right mouse selection will mask a Part. Ctrl + Shift and left mouse selection will unmask a Part Shift and hold the right mouse button and draw a window will mask all the parts within the window. Repeating the same process with the left mouse button will unmask the parts within the window. Model Browser: under Model pull down menu, click Model Browser:

In the Model Browser window, you can turn On/Off by checking/uncheking

The square box left to the Part or Assembly You can Display all by right mouse clicking on the Root Model and Click on Show or Hide

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HyperCrash Introduction 5

Chapter 1: Getting Started

Cross Reference in Model Browser:

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Chapter 1: Getting Started

Right mouse click on a Part or Assembly and click Cross Reference:

Creating Include File under Model Browser:

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HyperCrash Introduction 7

Chapter 1: Getting Started

Click on Model View

switch to Include-

. You then pick Submodel and ok. Anywhere on window, right mouse click anything youll like put in Include file with the middle mouse button drag it to the include file:

Section 5: Info Toolbar


The Info toolbar can be used to find information about the mesh: Show node info Show element info Show object info Find the distance between two nodes Node info by ID Element info by ID Object info by ID Find the angle between three nodes

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Chapter 1: Getting Started

Section 6: Tree Window


Use the Tree to navigate in your model hierarchy. Clicking the right mouse button (in the Notebook window) brings up a pop-up menu. Icons in the Tree Window and their meanings:

Assembly (subset) Here is the current state of the Tree toolbar:

Part

Subpart

Expand > Collapse All Expand/collapse tree Select > Unselect all Select / unselect all items Invert Selection Invert the selection Search Open the search panel to search for an Assembly, a Part or a Subpart Highlight Transparency for tree selection

Add to View Add the tree selection to the display Add to View and Resize Add tree selection to display and resize to fit Remove from View Mask tree selection from display View Only Isolate tree selections

Section 7: Help in HyperCrash


At any time, you can consult the HyperCrash online help. From the Pull-down Menu Bar, click Help and choose HyperCrash to open the online help in your web browser. Note: The HyperCrash help manual opens with Netscape (Mozilla under Linux platform).

Section 8: Description of the Example


The purpose of this example is to build an offset frontal crash model using HyperCrash

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HyperCrash Introduction 9

Chapter 1: Getting Started

Initial Velocity 35 MPH

Units: N, mm, s, Ton, Mpa

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Chapter 2: Introduction

Chapter 2

Introduction
Section 1: Open HyperCrash and Read the Input File
When you first start HyperCrash, the startup screen will appear (see following image):

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Chose the User profile, Choose whether you wish to run HyperCrash in the New or Classic mode, and choose the units environment you want to run the session in (for this tutorial, choose the Units System: N mm s T). Click on Run. Step 1: In the HyperCrash environment window, identify all the menus, windows, and toolbars described in Chapter 1. Step 2: Load the model called CAR35MPH_0000.rad 1. In the Menu Bar, click File >Import > RADIOSS file (see following image).

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2. In the Radioss Input window, select the file CAR35MPH_0000.rad and click OK (see following image).

Step 3: Use the mouse and keyboard (CTRL) options to move the model.

Zoom in and out

Translation

Rotation

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Chapter 2: Introduction

Section 2: Tree Structure / Hierarchy


Step 1: Create a new assembly called LEFT DOOR and put the entire left door* parts in it. 1. Click with the left mouse button in the Tree window (anywhere among assemblies). 2. Click the right mouse button and select New Assembly (see following image).

3. In the new window, enter LEFT DOOR and click Ok, as in the following image.

4. With the left mouse button, highlight the entire left door* parts.

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Chapter 2: Introduction

Note:

You may use the CTRL or SHIFT or CTRL+SHIFT keys to make the selection in the Tree easier.

5. Use the middle mouse button to drag the selected parts in the LEFT DOOR assembly.

Step 2: Create a new assembly called RIGHT DOOR and drag the entire right door* parts in it. 1. Click with the left mouse button in the Tree Window. 2. Click the right mouse button and select New Assembly.

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Chapter 2: Introduction

3. In the new window, enter RIGHT DOOR and click Ok. 4. With the left mouse button, highlight the entire right door* parts. 5. Use the middle mouse button to drag the selected parts in the RIGHT DOOR assembly. Step 3: Create a new assembly called DOORS and drag the two assemblies LEFT DOOR and RIGHT DOOR into it. 1. Click with the left mouse button in the Tree Window. 2. Click the right mouse button and select New Assembly. 3. In the new sub-window, enter DOORS and click Ok. 4. With the left mouse button, highlight the assemblies LEFT DOOR and RIGHT DOOR. 5. Use the middle mouse button to drag the selected parts into the DOORS assembly.

Step 4: Export the assembly called DOORS in RADIOSS V10.0 Block format. 1. In the Tree Window, highlight the assembly, DOORS.

You can view your selection by clicking the

icon.

2. Click the right mouse button and select Export Selection, as shown in the following image).

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Chapter 2: Introduction

3. In the Export Selection window:

Select Block 10.0 for the file format (default). Select the toggle, Save Only Geometry and click Ok.

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Chapter 2: Introduction

In the Write Block Format 100 RADIOSS File pop-up window, enter DOORS and click Ok. In the HEADER of RADIOSS pop-up window, click the Save Model button. The subsystem is exported. Click Close in the window called Write Engine file, V100.

Section 3: Delete a Part


Step 1: In the Tree Window, highlight the part called REAR_TIRE in the Wheels assembly. Step 2: Click the View Only button ( ).

Step 3: In the Tree Window, click the right mouse button and select Delete. Step 4: Answer Yes to the question in HyperCrash pop_up window (or press the ENTER key) to confirm deletion of the part.

Section 4: Mesh Class Definition


Five mesh classes are available in HyperCrash. From Class 1, defining very important parts (fine mesh, severe criteria), to Class 4, defining parts of low influence on the result precision (coarse mesh). If no class is defined for a part, HyperCrash automatically defines this part as Class s (s stands for standard). Step 1: In the Tree Window, highlight the subsets Frames and Front face (in the assembly Body in White) and click the View only icon ( ).

Step 2: In the Tree Window, click the right mouse button and select Class Selection, then, Class 1 (see following image).

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Chapter 2: Introduction

Step 3: Repeat step1 and step2 to define the assemblies Front suspension, Wheels, and Subframe as Class 2. Step 4: Repeat step1 and step2 to define the assemblies Body (in the assembly Body in White) and DOORS as Class 3. Step 5: Repeat step1 and step2 to define the assemblies Rear (in the assembly Body in White), Rear suspension, and others as Class 4. Step 6: Click Display All ( ) and Fit Model ( the Graphic Window. ) buttons to display the whole model in

Step 7: Make sure to save the Model at the end of each chapter: Click on file Export ___> Radioss __> enter file Name: CHPT2

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Chapter 2: Introduction

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Chapter 3: Material and Property Allocation

Chapter 3

Material and Property Allocation


Following the steps in Chapter 2, Section 1, load the model called CHPT2_0000.rad.

Section 1: Create Material


Step 1: From the Pull-down Menu Bar, click Model, then Material.

Step 2: In the Material panel, click the RADIOSS menu, choose Elasto-Plastic, then select Johnson Cook (2).

Step 3: In the fields in the lower section of the Material panel, enter the following parameters: Title: high_steel

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Chapter 3: Material and Property Allocation

Initial Density: 7.9e-09 Youngs Modulus: 210000 Poissons Ratio: 0.3 Yeild Stress: 250 Hardening Parameter: 500 Hardening Exponent: 0.5 Step 4: Click See Curve ( ) to plot the true stress v. true strain curve.

Step 5: Close the plot.

Step 6: Click the Save in database button (

).

Step 7: In the Save in Data Base window, delete the path to the global database, enter the path to your local data base or working directory then enter high_steel, as name. Note: By default, HyperCrash points to the global database. You do not have permission to write here but you can create your own local database.

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Chapter 3: Material and Property Allocation

Path to your Local database

Step 8: Click OK to save your material in your local database. Step 9: Click Cancel and Close to close the Material menu.

Section 2: Modify Materials


Step 1: From the Pull-down Menu Bar, click Model and choose Material. Step 2: switch to the Tree Window, highlight the part ENGINE_MOUNT1 (in the assembly Body in White Frames).

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Chapter 3: Material and Property Allocation

Step 3: Click on Isolate Tree Selection (

).

Step 4: Go back to the Material panel and click on pick part to see and select corresponding item in list ( Selected button ( ). ), select the display item then Yes and click on See

Step 5: Click the See Curve icon ( ) on the lower part of the panel. The Plot Window opens. Click Close to close the curve after reviewing it.

Step 6: Modify the following parameters: Title: low_yield_steel Yield Stress: 165 Hardening Exponent: 0.5

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Chapter 3: Material and Property Allocation

Step 7: Click See Curve ( ) to plot the new stress v. strain curve. Click Close to close the curve after reviewing it.

Step 8: In the Material Properties panel, click Save. Step 9: Click Close to close the Material panel.

Section 3: Material Allocation


Note: You can allocate materials from the global database or local database, or you can even pick existing materials from within the model. Step 1: From the Pull-down Menu Bar, click Model and choose Material. Step 2: In the Material panel, select the Switch between Model & DB icon ( click the Go to Home Database directory icon ( Step 3: Allocation from the Global Database. 1. Select STEEL material and click the See Selected icon ( ) (see following image). ). ). Then

2. The material parameters appear.

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Chapter 3: Material and Property Allocation

3. Go to the Tree panel, highlight the part CBN-SEAT-REINF-FT (in the assembly Body in White Frames) and click the Isolate Tree Selections icon ( ).

4. Go back to the Material panel and click the Selected parts of tree icon ( 5. Click Save to allocate the material. Step 4: Allocation from the Local Database. 1. In the Modify panel, select Switch between Model & DB(

).

) twice. Then click the

), enter the path to your local database or Change the database directory icon ( working directory and click the OK button. 2. Highlight high_steel_0000.rad and click the See selected icon ( material parameters. ) to see the

3. Go to the Tree panel, highlight the part RAILS_R (in the assembly Body in White Frames), and click the Isolate Tree Selections icon ( ). ).

4. Go back to the Material panel and click the Selected parts of tree icon ( Step 5: Allocation from the Model.

5. Click Save to allocate the material and click Close to close the Material panel.

). 1. Go to the Material panel, select rubber material and click the See selected icon ( Only the parts assigned to the material rubber are displayed in the Graphic Window.

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Chapter 3: Material and Property Allocation

2. In the Tree Window, highlight the parts TIRE-FT-L and TIRE-FT-R (in the assembly Wheelsfront_wheel) and click the Isolate Tree Selections button ( 3. Go back to the Material panel, click the Include picked parts button ( tires from the Graphic Window. ). ), and pick the

4. After selecting both tires, confirm the selection by clicking Yes in the Dialog Menu Bar (lower-right corner of the HyperCrash window). 5. Click Save to allocate the material (confirm in the Dialog Menu Bar) and click Close to close the Material panel.

Section 4: Create Properties


Step 1: From the Pull-down Menu Bar, click Model, and choose Property.

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Step 2: In the Property panel, click the RADIOSS menu, choose Surface, and select Shell (1).

Step 3: Enter the following parameters as in the following image: Title: shell_1.1mm Number of Integration Points: 5 Thickness: 1.1

Step 4: Click the Save in database icon ( Note:

).

Step 5: In the Save in data base sub-window, navigate to your local database By default, HyperCrash points to the global database. You do not have permission to write here, but you can create your own local database.

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Chapter 3: Material and Property Allocation

Step 6: Click OK to save your material in your local database (see following image). Step 7: Click Cancel and then click Close to close the Properties panel.

Section 5: Modify Properties


Step 1: From the Pull-down Menu Bar, click Model and choose Property. Step 2: In the Tree Window, highlight the part ENGINE_MOUNT1 (in the assembly Body in White Frames) and click the Isolate Tree Selections icon ( ).

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Chapter 3: Material and Property Allocation

Step 3: Click on Isolate Tree Selection (

).

Step 4: Go back to the Property panel and click on pick part to see and select corresponding item in list ( Selected button ( ). ), select the display item then Yes and click on See

Step 5: The property parameters appear in the panel: Modify the following parameters: Title: Engine_Mount_2.0mm Nb Integration Points: 5 Thickness: 2.0 Step 6: Click Save and Close to close the Property panel.

Section 6: Property Allocation


Note: You can allocate properties from the global database or local database, or you can pick existing properties from within the model. Step 1: From the Pull-down Menu Bar, click Model and choose Property. Step 2: In the Property panel, select the Switch between Model & DB icon ( click the Go to Home Database directory icon ( Step 3: Allocation from the Global Database. 1. Select SOLID GENERAL and click the See selected icon ( ). ). ). Then,

2. The property parameters appear as follows:

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Chapter 3: Material and Property Allocation

3. In the Tree Window, highlight the part ENG-MNT-BUSH-L (in the assembly Body in White Frames) and click the Isolate Tree Selections icon ( ).

4. Go back to the Property panel and click the Selected parts of tree icon ( 5. Click Save to allocate the property. Step 4: Allocation from the Local Database 1. Go to Property panel and select the Switch between Model & DB icon (

).

). Then,

), enter the path to your local database or working directory click the Folder icon ( and click the OK button. 2. Select shell_1.1mm_0000 as in the following image and click the See Selected icon ( ).

The property parameters appear.

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3. In the Tree Window, highlight the part LEFT RAIL 2 (in the assembly Body in White Frames) and click the Isolate Tree Selections icon ( ). ).

4. Go back to the Property panel and click the Selected parts of tree icon ( 5. Click Save to allocate the property. Step 5: Allocation from the Model

) to switch to the 1. In the Property panel click the Switch between Model & DB icon ( model database. Then, select Engine_Mount_2.0mm property number 21 as in the following image and click the See selected icon ( ).

2. In the Tree Window, highlight the parts TIRE-FRT-L and TIRE-FRT-R (in the assembly Wheels) and click the Isolate Tree Selections button ( ). ),

Step 6: Go back to the Property sub-panel, click the Include picked parts button ( and pick the tires in the Graphic Window.

Step 7: Confirm the selection by clicking Yes in the Dialog Menu Bar (lower-right corner of the HyperCrash main window). Step 8: Click Save in the properties panel to allocate the property and answer Yes to the question in the Dialog Menu Bar, New PARTS have been selected. Do you want to continue? Then, click Close to close the properties panel.

Section 7: Mat & Prop Allocation from the Tree Window


Step 1: In the Tree Window, highlight the assembly called RIGHT_DOOR and click the Isolate Tree Selections button ( Step 2: ).

In the Tree Window, click the right mouse button and select List Selection.

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Chapter 3: Material and Property Allocation

Step 3: In the Selection List Window, click the right door dr2outer part to highlight it. Step 4: Click the right mouse button and select Change Thickness.

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Step 5: In the Change Thickness pop-up panel, enter 1.20 and click Ok (see following image).

Step 6: In the Selection List Window, click the RIGHT_DOOR assembly to highlight it. Step 7: Click the right mouse button and select Change Material.

Step 8: In the Material File Window, select STEEL and click OK. The PLAS_JOHNS Material curve (Stress vs. Strain) will appear:

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Chapter 3: Material and Property Allocation

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Step 9: Click Save in the PLAS_JOHNS window. To confirm the curve, click Yes in the Dialog Menu Bar.

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Note:

You can modify the material law parameters and click Apply to update the curve.

Step 10: See the Selection List Window to view the results. Step 11: Explore the different options available in the Selection List Window. Step 12: Click Close in the List Selection Window. Step 13: In the Model Display menu, click the Display All ( ( ) or (Ctrl+S) and Fit Model

) or (Ctrl+R) icons to display the whole model in the Graphic Window.

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HyperWorks 10.0

Chapter 4: Element Creation/Modification

Chapter 4

Element Creation / Modification


The purpose of this chapter is to create and modify elements with HyperCrash. Following the steps in Chapter 2, Section 1, load the model called CHPT3_0000.rad.

Section 1: Create New Elements


Step 1: In the Tree Window, highlight the part called RAILS-U-FT-O-R (in the assembly Body in White Frames). Step 2: Click the Isolate Tree Selections button ( ).

Step 3: From the Pull-down Menu Bar, select Mesh Editing, Node, then Create.

. Step 4: In the Mesh Editing panel, select the Copy sub-panel:

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Step 5: Zoom in on the area depicted in the following image (using the center mouse button to select the nodes to duplicate, and click Yes in the button), click the Dialog Menu Bar after the last node for duplication selection is done.

Step 6: Click the rail.

button to define the displacement vector and click two nodes on the

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Step 7: View the translation with the See translation button (

) and click Save to save it.

Step 8: Follow Steps 6 to 8, selecting the appropriate nodes to obtain the result below then close node creation:

Step 9: In the Mesh Editing Panel, use the drop-down menu to choose the Element/Create sub-panel. Step 10: Click the Include picked part button ( Graphic Window (RAILS-U-FT-O-R). ) and select the part displayed in the

Step 11: From the drop-down menu, choose element type to create and select Shell4n and-or Shell3n. Then, select the nodes to create new elements.

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Step 12: Press ESC or click Cancel in the Dialog Menu Bar when the element creation is. Completed. Next, click Save and then click Close to close the Mesh Editing panel.

Section 2: Modify Elements


Step 1: In the Tree Window, highlight the part called RAILS-U-FT-O-R (in the assembly Body in White Frames). Step 2: Click the Isolate Tree Selections button ( Step 4: In the Mesh Editing panel, select 2D: ).

Step 3: From the Pull-down Menu Bar, select Mesh Editing, then Element, then Modify.

Step 5: Zoom in on the designated area (using the middle mouse button). Click the Split Shell 4 nodes in 2 shells 3 nodes button ( ). Select one element and one node, and click Save to confirm. When finished, press ESC or click Cancel in the Dialog Menu Bar.

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Chapter 4: Element Creation/Modification

Step 6: Delete the elements on the edge. 1. Click the Add/Remove elements by picking selection button ( ), and, in the Graphic Window, select the elements that you want to delete and click Yes in the Dialog Menu Bar to end the elements selection. 2. Delete the elements by clicking the Remove selected shell 4 nodes or shell 3 nodes icon ( panel. ) and click Yes in the Dialog Menu Bar to return to the Modify > Element

3. Click Cancel in the Dialog Menu Bar to complete element selection. 4. Click Close to close the Modify/ Element panel.

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Section 3: Split a Part into Two Parts


HyperCrash allows you to split a part into two parts. Step 1: In the Tree Window, highlight the parts called RAILS-U-FT-O-R (in the assembly Body in White Frames). Step 2: Click the Isolate Tree Selections button ( ).

Step 3: From the Pull-down Menu Bar, click Mesh Editing, then Part, then Split. Step 4: Click the Include picked parts button ( the part to be split (RAILS-U-FT-O-R). ), and, in the Graphic Window, select ), and, in the Graphic

Step 5: Click the Add elements by box selection button ( Window, select the elements as shown below.

Note:

Apply the view shown above for the selection to avoid left/right confusion.

Step 6: Select the toggle, Create new Part. Step 7: In the New part name field, enter the name RAIL-U-FT-O-L and click Ok (see following image). Step 8: Keep the same thickness and the same material (see following image). Step 9: Click Save and then Close to return to the main menu.

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Chapter 4: Element Creation/Modification

Note:

The old part and the new one are grouped in special group of parts named New_physical_part as shown, following. It is not possible to move the parts out of this group.

Section 4: Create a Reinforcement


Step 1: In the Tree Window, highlight the parts called RAIL-U-FT-O-L (in the assembly Body in White Frames New_physical_part). Step 2: Click the Isolate Tree Selections button ( Step 4: In the Mesh Editing panel, select Stiffner. Step 5: Enter the name of the reinforcement, REINF_L, and click OK. Step 6: Select the part: click , then pick the part in the graphic window, and validate in icon to choose the elements to be offset to create ).

Step 3: From the Pull-down Menu Bar, select Mesh Editing, then Part, then Sheet.

the dialog window. Use the the new part.

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Step 7: In the Material section of the panel select the toggle to keep the same material. In the Property section, keep the same thickness value; you can change it by entering a new value. Step 8: In the Translation section of the panel, select a normal to elements translation. Step 9: In the Offset section of the panel, enter an offset value of 1.2 and press OK (see following image) to check the result which is an outer reinforcement. (A negative offset value here would create an inner reinforcement.)

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Step 10: Click Save, then click Close to close the panel.

Section 5: Create a Symmetry of a Part


Step 1: In the Tree Window, highlight the part called REINF_L. Step 2: Click the Isolate Tree Selections button ( ).

Step 3: From the Pull-down Menu Bar, select Mesh Editing, then Part, then Duplicate. Step 4: Using the Include picked part button ( (Yes in the Dialog Menu Bar). ), select the part, REINF_L, and confirm

Step 5: From the Options pull-down menu, select Mesh only. Step 6: Click the Mirror icon ( ).

Step 7: Click Apply mirror, click Save, and then click Close to close the panel.

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Note:

The created part is located in the Duplicated parts assembly in the Tree Window.

Step 8: We need to attach the reinforcement to the frame: Go to mesh Editing

Enter Left_ Reinf. Rigid Body as name and click ok. Click on ( ) to select the rigid body slave nodes; after selecting, click yes to complete the selection then Click on Save. Repeat The same step to attach all the reinforcement plates, and close Mesh Editing.

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HyperWorks 10.0

Chapter 5: Connections

Chapter 5

Connections
Following the steps in Chapter 2.1, load the model called CHPT4_0000.rad.

Section 1: Read a Spotfile file (MWF Format)


Step 1: In the Display Toolbar click the Display All ( display the whole model. ) and Fit Model ( ) icons to

Step 2: From the Pull-down Menu Bar, select Connections, then click Spotweld, then Import from File. Step 3: In the spotweld file window, select the file, spotfile (see following image), and click OK .

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Step 4: While HyperCrash is automatically creating the spotwelds, you can open the file called spotfile with the editor of your choice and view the format. Step 5: As soon as HyperCrash completes the spotweld creation, correct the few bad spotwelds: Note: The bad spotwelds are highlighted in red in the Spotweld > Modify sub-window (see following image). HyperCrash declares a spotweld bad when it does not meet the specified weld criteria, see below

1. In the Spotweld > Modify panel, click the first bad spotweld.

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2. Click the See selected spotweld(s) button ( Window.

) to display the spotweld in the Graphic

) in the Display Toolbar to see the parts and the bad Click the Fit Model button ( spotweld location (small yellow and red sphere: ).

Bad spotweld location. Parts 137 & 138 Should be welded

3. Select the Location > Element tab. 4. Click the Pick one shell element and see spotweld button ( ).

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5. In the Graphic Window, click an element to define the new location for the spotweld. If the new location is acceptable, two green elements and a blue spotweld appear on the screen. 6. Click Save to confirm the new location. An acceptable spotweld is created and the (uncreated) bad spotweld is automatically removed from the red color list)

Bad spotweld

5: Click this element The green color means that HyperCrash can create the spotweld at this new location

6: Saved spotweld Two red elements = RADIOSS interface type 2 Two green nodes + one blue spring = RADIOSS spring type 13

7. Repeat Steps 1 to 6 to correct or eliminate all the bad spotwelds (red color list) and then close the panel.

Section 2: Display Spotweld Options


Step 1: In the Pull-down Menu Bar, click Spotweld, then Modify. Step 2: In the Tree Window, highlight the part called right door-FT-O-R (in the assembly, DOORS RIGHT DOOR). Step 3: Click the Isolate Tree Selections button ( ).

Step 4: In the Spotweld > Modify panel, click the Include picked parts button Step 5: In the Graphic Window, click the displayed part and validate the selection with Yes. All the spotwelds that belong to this part are displayed.

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Note: All the spotwelds that belong to the selected part are highlighted in the Spotweld > Modify panel. Press SHIFT+F8 to hide the spotwelds from the screen, and click Close to close the panel.

Step 6: In the Tree Window, highlight the same part (right door-FT-O-R). Step 7: Click the right mouse button and select Connections.

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Step 8: The spotweld connections that belong to this part are displayed in the small Notebook Window. Step 9: In the Notebook Window, right-click the spotweld connections to display, undisplay, and clear the spotwelds from Graphic Window. Note: When selecting an assembly, the Internal Connections and External Connections options are available. Internal Connections searches for the connections between the parts of the selected assembly. External Connections searches for the connections between the parts of the selected assembly and the rest of the model.

Section 3: Spotweld Checking


Step 1: In the Pull-down Menu Bar, click Spotweld, then Criteria. Step 2: In the Check Criteria Window, select the criteria you want to check and enter the values you want for each parameter (it is recommended to use the default values as depicted in the image below). Spring Length Min: 0.1 mm Spring Length Max: 10 mm Angle Max: 15 degrees Time Step: 8e-7 s

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Step 3: In the Drop-down Menu Bar, click Spotweld, then Check.

Note: The spotwelds beyond the selected criteria are highlighted (orange list) in the Spotweld > Check panel. They will be referred to as marginal spotwelds. Step 4: Select one marginal spotweld in the orange list and click the button.

Step 5: See the message in green in the Message Window (lower-left corner of HyperCrash main window) to learn why this spotweld is considered marginal.

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Step 6: Modify the spotweld. Note: button, the spotweld and its attached parts are displayed in When you click the the Graphic Window. Changing the location of the spotweld is likely to correct the spotweld as in the example below. Follow steps 3 to 6 to do so.

HyperCrash proposal

Relocation of the spotweld

The new spotweld is created

Step 7: Repeat step 3 to 6 for the other marginal spotwelds. Step 8: Click Close to close the Spotweld > Check panel.

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Section 4: Create a Few New Spotwelds


Step 1: From the Pull-down Menu Bar, click Connections, then Spotweld, then Create. Step 2: In the Tree Window, highlight the parts called right door-FT-I-R and right door-FT-O-R. Step 3: Click the Isolate Tree Selections button ( ).

Step 4: Go back to the Spotweld > Create panel and click the Include parts by box button ( ).

Step 5: In the Graphic Window, drag a box to select the two parts. Step 6: In the Element sub-panel, click the Pick one shell element and see spotweld button ( ).

Step 7: In the Graphic Window, click an element to weld the two parts. Two green elements and a blue spotweld appear on the screen. Step 8: To save this spotweld, click Save in the Spotweld > Create panel. The spotweld is created. Step 9: Repeat step 7 and 8 to create a few more spotwelds on the two parts.

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7: Click an element Green means that HyperCrash can create the spotweld at this location Note:

8: Saved spotweld Two red elements = interface type 2 Two green nodes + one blue spring = spring type 13

You can also click the Node sub-panel and click nodes in the Graphic Window or the Line sub-panel to automatically create spotwelds between two nodes or two elements with a certain pitch length.

Step 10: Click Cancel in the Dialog Menu Bar to stop the selection.

Section 5: Export a New Spotweld File


Step 1: In the Pull-down Menu Bar, click Connections, then Export File, and select All Spotwelds with Property Id.

Step 2: In the Export connection file with property Id window, enter Spotfile2 and click OK (see following image).

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Step 3: Click Close to close the Spotweld panel and return to the main window.

Section 6: Bolt Creation


Step 1: From the Pull-down Menu Bar, select Connections, then click Bolt and select Create.

Step 2: In the Tree Window, highlight the part, RIGHT-ARM (in the assembly Front suspension) and the parts RIGHT-SUBFRAME-1 and RIGHT-SUBFRAME-2 (in the assembly Subframe). Step 3: Click the Isolate Tree Selections button ( ).

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Step 4: Go back to the Bolt > Create panel. The First Set button ( activated, so click the Include picked parts button ( ).

) is already

Step 5: In the Graphic Window, click the part, RIGHT-ARM to highlight it. Click Yes in the Dialog Menu Bar to confirm the selection. Step 6: Click the Second Set button ( parts button ( ). ) to activate it, then, click the Include picked

Step 7: In the Graphic Window, click the parts RIGHT-SUBFRAME-1 and RIGHTSUBFRAME-2 to highlight them. Click Yes in the Dialog Menu Bar to confirm the selection. Step 8: In the Location panel, select the Node sub-panel. Step 9: Enter the following coordinates: X = 3782, Y = 400 and Z = 187 (see following image).

). A blue cylinder appears in Step 10: Click the Put coordinates and see bolt button ( the Graphic Window. This cylinder represents the bolt.

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Step 11: Select the Direction sub-panel and uncheck the Normal to element(s) toggle. Step 12: Enter the X, Y, and Z coordinates, X = 1 Y = 0 Z = 0 to define the bolt direction (see following image). Then, press the ENTER key. The bolt moves to the correct direction.

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Step 13: In the Properties section, enter RIGHT REAR FIXING for the Bolt Name, 40 for the Length 1, 40 for the Length 2, and 60 for the Diameter (see following image). Then, press the ENTER key.

Note:

When you press the ENTER key, the nodes included in the blue cylinder become red. Those nodes will be part of the bolt.

Step 14: Click the Bolt with spring toggle to activate it (see the note, following). Step 15: Click Save and then Close to return to the main menu. Note: When you click save, the bolt becomes yellow and two red rigid bodies and a small green spring appear on the screen. Press SHIFT+F8 to hide the bolt from the Graphic Window.

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Chapter 5: Connections

Section 7: Tied Interface Creation


Step 1: From the Pull-down Menu Bar, select LoadCase and click Contact interfaces, then Create/Modify.

Step 2: In the Choose Contact section of the panel, click the pull-down menu and select Kinematic Condition (Type 2). Step 3: Click the Properties tab, and in the Title field, enter the name Windshield_Connection, as shown in the following image.

Step 4: Click the Selection tab and select Slave from the options. Step 5: In the Tree Window, highlight the WINDSHIELD-FT part (in the assembly Body in White Body) and click the Isolate Tree Selections button ( ). Step 6: Go back to the Contact > Create panel and select the slave nodes as shown below (by picking ( ) or by box ( )).

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Step 7: On the Selection panel, select the toggle, Master. Step 8: In the Tree Window, highlight the CBN-OUTER-R part (in the assembly Body in White Body) and click Isolate Tree Selections ( ). ) or

Step 9: Go back to the Contact > Create/Modify panel and select (by picking ( by box ( )) the master elements as follows:

Step 10: In the Tree Window, highlight the CBN-OUTER-L part (in the assembly Body in White Body) and click the Isolate Tree Selections button ( ). ) or

Step 11: Go back to the Contact > Create/Modify panel and select (by picking ( by box ( )) the master elements on the other side.

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Step 12: Click Save and Close to close the Contact Interface panel.

Section 8: Check the Model Connections


Step 1: In the Tree Window, select the whole model. Step 2: In the Pull-down Menu Bar, select Quality, then Check Connectivity of Tree Selection. This menu allows you to find if a part is not connected to the rest of the model (that is, a free part).

Step 3: Click the Expand/Collapse all button (

).

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), and then select a Step 4: Click the See parts connectivity to picked part button ( part in the Graphic Window. You will see all the parts connected to the picked part in the Notebook Window. When finished, click Cancel in the Dialog Menu Bar. Step 5: In the part group list, click one group to highlight it, then click the Isolate Tree Selections button ( ) to display it on the screen. ) buttons to display the whole model in

) and Fit Model ( Step 6: Click Display All ( the Graphic Window.

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Chapter 6: Merge and Connect Subsystems

Chapter 6

Merge and Connect the Subsystems


The purpose of this chapter is to merge subsystems with HyperCrash and to manage the model mass. Following the steps in Chapter 2, Section 1, load the model called CHPT5_0000.rad.

Section 1: Read the Engine File


Step 1: Click the Display All ( ) and Fit Model ( model in the Graphic Window. Step 3: In the HyperCrash window select Merge. ) buttons to display the whole

Step 2: In the Pull-down Menu Bar, click File, Import then RADIOSS

Step 4: In the Select a RADIOSS File window, select ENGINE_0000.rad and click OK (see following image).

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Step 5: In the Offset Values section of the Merge panel,since the engine and transmissions coordinates are already correct. click Merge to merge the engine and transmission.

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Note: The merged subsystem is highlighted in the Graphic Window. Click the Refresh button ( ) to return to a normal display.

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Section 2: Connect the Engine and the Transmission


Step 1: In the Tree Window, highlight the parts called ENGINE_MOUNT1 (from the assembly Body in White Frames) and ENGINE (from the assembly Engine).

Step 2: Click the Isolate Tree Selections button (

).

Step 3: From the Pull-down Menu Bar, click Mesh Editing, then Rigid Body, then Create.

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Step 4: Enter the name LEFT ENGINE MOUNT (see following image) and click Ok.

Step 5: In the Selections panel, use the different selection icons to set your node selection as shown in image below. Step 6: In the Graphic Window, zoom in on the left engine mount ENGINE_MOUNT1, and select a few nodes.

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Step 7: Click Save to save the selection. Note: Buttons are available to help you select or deselect slave nodes during the rigid body definition. Use the F6 key as a switch to display or hide the rigid bodies in the Graphic Window.

Step 8: Click Close in the Rigid body panel to return to the main window. Step 9: In the Tree Window, highlight the parts called CONNECTION (from the assembly Front suspension) and FR_AXLE (from the assembly Engine). Step 10: Click the Display Tree Selections button ( ).

Step 11: In the Pull-down Menu Bar, click Mesh Editing, then Node, then Modify.

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Step 12: Select the Merge multi sub-panel.

Step 13: Click the toggle Set1 and click the Include picked part button ( Step 15: Click Yes in the Dialog Menu Bar to confirm the selection. Step 16: Click the toggle Set2 and click the Include picked part button ( Step 17: In the Graphic Window, pick the part FR_AXLE to highlight it. Step 18: Click Yes in the Dialog Menu Bar to confirm the selection.

).

Step 14: In the Graphic Window, pick the part CONNECTION to highlight it.

).

Step 19: In the gap search to merge field, enter the value, 0.2 and click the See Node(s) to merge Selections button ( suggests for you to merge. ). HyperCrash highlights in red the nodes that it

Step 20: To merge the suggested nodes, click Save.

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HyperCrash highlights the node(s) it suggests to merge. Step 21: Click Close in the Merge Multi panel to return to the main window.

Section 3: Check the Mass Balance of Your Model


HyperCrash allows you to check the model mass and adjust it according to the real mass of the vehicle. Assume that the values are coming from the tests: Tested vehicle mass = 0.7 T Weight on front axis = 0.443395 T Weight on rear axis = 0.256605 T Step 1: From the Pull-down Menu Bar, click Mass Balance and select Compute and manage model mass.

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Step 2: HyperCrash gives you information about the model mass and the center of gravity (COG). Step 3: Click to enter the theoretical mass of your vehicle: 1.24156 T. Click OK.

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Step 4: Enter the X coordinates of the front and rear axles: Xfront = 3750mm XRear = 1062mm Note: These values can be entered using the Determine axles by picking node button ( ). to view the mass on the front and rear axles.

Step 5: Click

Step 6: Modify theses values with respect to the test results: Weight on front axle = 0.515589 T Weight on rear axle = 0.448653 T to choose the added Step 7: You can select Added mass to modify by clicking masses to which the modifications will apply and those to which they will not apply. Note: button opens the following panel in order to include your mass distribution the selection among the available added masses. To save your choices, click Save Configuration. You may print a report by clicking Print.

Step 8: To close the window without saving any changes, click Cancel All.

Step 9: On the Added Mass Management panel, click Step 10: Click

to modify the car mass.

to see the modifications to the different added masses.

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Step 11: Click Save to save the modifications and Close to close the panel.

Section 4: Merge the Barrier


Step 1: In the Pull-down Menu Bar, click File, Import__> RADIOSS then Merge.

Step 3: Select ODBBLD00 and click OK.

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Section 5: Move the Barrier to its Correct Location


Step 1: Check the Apply Transformation then in the Translation along values: enter X = 1576, Y = 14, and Z = 624 (see following image), and click Merge to reposition the barrier in the correct location.

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Chapter 7: RADIOSS Features

Chapter 7

RADIOSS Features
The purpose of this chapter is to create some RADIOSS features such as boundary conditions, interfaces, initial velocity, added mass and rigid walls. Following the steps in Chapter 2, Section.1, load the model called CHPT6_0000.rad.

Section 1: Create a Boundary Condition


Step 1: From the Pull-down Menu Bar, select LoadCase, then Boundary Conditions, then Create.

Step 2: In the field provided, enter the name FIX_ODB (see following image) and click OK.

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Step 3: Use the F6 key to display the rigid bodies. Step 4: In the Graphic Window, zoom in at the back of the barrier to clearly locate its master node (see image, following). Then, click the Add/Remove nodes by ) to select the ODB rigid body master node in the picking selection button ( Graphic Window (it turns red). Step 5: Click Yes in the Dialog Menu Bar to confirm the selection. Step 6: In the Boundary condition components section of the Create panel, toggle all translations and rotations to fix all the degrees of freedom for this node. Step 7: Click Save and then Close to return to the main menu.

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Section 2: Create an Interface to Handle the Contacts for the Car


Step 1: From the Pull-down Menu Bar, select LoadCase and click Contact interfaces, then Create/Modify.

Step 2: Using the Choose Contact pull-down menu, select Multi usage (Type 7). Step 3: Click the Properties tab. In the field, Title, enter the name CAR_CAR (see following image).

Step 4: Click the Selection tab, and select the surface choice, Self-Impact (see following image).

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Step 5: In the Tree Window, select all the assemblies and parts of the model except ODB assembly and click the Isolate Tree Selections button ( ).

Step 6: Go back to Contact Interface panel, and use the Add selected parts by box button ( ) to select elements.

Step 7: In the Graphic Window, drag a box to select the following elements:

Note:

The selected elements are highlighted in red.

Step 8: In the Properties sub-panel, enter the following values (see following image): Coulomb friction = 0.2 Scale factor for stiffness = 1.0 Min. gap for impact activ, = 0.7 For Friction penalty formulation set to Stiffness

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Step 9: Click Save and then Close to return to the main menu.

Section 3: Create an Interface to Handle the Contacts between the Car and the Barrier
Step 1: From the Pull-down Menu Bar, select LoadCase and click Contact Interf. > Create/Modify. Step 2: Using the Choose Contact pull-down menu, select Multi usage (Type 7). Step 3: Click the Properties tab. In the Title field, enter the name CAR_BARRIER. Step 4: Click the Selection tab. From the surface options, select Slave. ) and drag a box around the front Step 5: Click the Add selected parts by box button ( of the car as shown in the example, following (the parts are highlighted in red).

Step 6: Next, select Master from the surface options. Step 7: In the Tree Window, highlight the following parts in the ODB assembly and click the Isolate Tree Selections button ( ):

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Step 8: Go back to the Contact panel, click on (

) to show the solid external face only. ).

In the Selections sub-panel, click the Add selected parts of Tree button ( Step 9: In the Properties sub-panel, enter the following values: Coulomb friction = 0.2 Scale factor for stiffness = 1.0 Min. gap for impact activ. = 0.7 For Friction penalty formulation set to Stiffness

Step 10: Click Save+sym. (see the next Note) and then Close to return to the main menu. Note: When you click the Save+sym. button, HyperCrash saves the defined interface and automatically creates its symmetric: the slave surface becomes master surface, and the master surface becomes slave surface. The Save+sym. option is not available for a Self-Impact interface. The extension _sym is added to the symmetric interface name. Interface CAR_BARRIER_sym

Interface CAR_BARRIER

Master

Slave

Slave

Master

Section 4: Create an Initial Velocity to Apply to the Entire Car


Step 1: From the Pull-down Menu Bar, select LoadCase and click Initial Velocities, then Create.

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Step 2: Enter 35 MPH for the title and click OK. Step 3: In the Tree Window, highlight all the assemblies and parts except ODB. Step 4: Go back to the Initial Velocity panel, click the Add selected parts of Tree button ( ). All the nodes are highlighted except the ODB nodes.

Step 5: In the Translation Components field, enter Vx = +15646.4 as shown in the following image (15646.4 mm/s = 35 MPH).

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Step 6: Click Save, answer Yes to the question in the Dialog window, and then click Close.

Section 5: Create an Added Mass on the Right Door


Step 1: From the Pull-down Menu Bar, select LoadCase and click Added Masses, then Create.

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Step 2: Enter the name Door 5 kg and click OK. Step 3: For the selection, click the Include picked parts button ( ).

Step 4: In the Graphic Window, click the right door inner part (it becomes red).

. Step 5: Click Yes to confirm the selection in the Dialog Menu Bar. Step 6: Enter 0.005 in the Mass field as shown in the following image (0.005 T = 5 kg). Note: The mass is equally distributed on all the selected nodes.

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Step 7: Click Save and then Close to return to the main menu.

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Section 6: Create a Rigid Wall to Model the Ground


Step 1: From the Pull-down Menu Bar, select LoadCase and click Rigid Walls, then Create.

Step 2: From the Rigid Walls drop-down menu, select Infinite Plane. Step 3: In the Rigid wall name field, enter the name GROUND as shown in the following image. Step 4: Enter the following values for M0 and M1 as shown in the following image: M0 X = 0 M1 Y=0 Z = 5.9 X=0 Y=0 Z =10

Step 5: In the Section sub-panel, in the Distance for search of slave nodes field, enter a value of 200mm (see following image).

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Note:

You can use the selection icons to add or remove nodes from the rigid wall selection.

Step 6: Switch to the Properties sub-panel. Step 7: For the Friction Parameters, keep the Sliding option. Step 8: Select the Fixed option. Step 9: Click the see button. Step 10: Click Save and then Close to return to the main menu.

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Chapter 8: Quality Check

Chapter 8

Quality Check
The purpose of this chapter is to show you how to use the Quality module in HyperCrash. Following the steps in Chapter 2, Section.1, load the model called CHPT7_0000.rad.

Section 1: Check Intersections and Penetrations in Your Model


Step 1: From the Pull-down Menu Bar, click Quality, then Check All Interfaces and wait for HyperCrash to find all the interfaces. This may take a few seconds.

Note:

You can check the interfaces one-by-one using the Check selected interface button in the Loadcase, Contact interf. > Create/Modify menu.

Step 2: In the Quality > Contact panel, toggle Intersection at the top of the panel and select the CAR_CAR interface.

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Step 3: On the lower part of the Contact panel, select one intersection at a time and view each in the Graphic Window.

Note: It is easier to see the intersections if the model is in Poly. + Line view (from the Display menu). You may also adjust the level of transparency using the Control transparency level icon ( Note: ).

) if you want to return to a normal display. Select the Click the Refresh button ( CAR_CAR interface from the list at the top of the Contact panel. ) to select all the intersections in part

Step 4: Click the Select/Unselect All button ( pairs.

Step 5: Click the Remove Intersections button ( ) to launch the automatic intersection correction. This may take a few seconds to complete.

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Initial state: 15 intersections in part pairs. Int. shows the number of intersections in each part pair. At the end of the automatic intersection correction, only two remain. Those intersections have to be corrected manually (see following).

Step 6: Click the first remaining intersection to highlight it. Step 7: Click one of the following buttons to move the nodes and remove the intersection. Click: to move one or several nodes in the plane defined by the neighboring elements to move one or several nodes in the plane defined by the first selected node and two other nodes to move one or several nodes along the normal of the plane defined by the first selected node and two other nodes to move one or several nodes in the plane defined by the screen Step 8: Click the Recheck Intersections button ( ). If the problem is solved, the intersection is removed from the list and HyperCrash automatically continues to the next intersection. If the problem is not solved, repeat the steps 7 and 8 in order to move the nodes and correct the intersection. Step 9: Validate the node picking and moving in the Dialog Menu Bar. Note: While you are moving a node, the quality of elements around the node is shown in color: Green = good Orange = acceptable Red = bad Note: Sometimes, HyperCrash suggests displacements by displaying arrows:

To perform these displacements, click the Remove Intersections button ( move the nodes automatically. If you want to decline the proposed displacements, click the button.

) to

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If you want to delete an arrow, click the button, then click a node that displays an arrow (node is highlighted) in the Graphic Window, and validate with Yes in the Dialog Menu Bar.

Step 10: Click the Check Penetrations button ( ) to check the penetrations and select the Penetrations toggle at the top of the panel to switch to the penetration page. Step 11: In the Gap Interface field, the gap value input in the interface definition will be shown by default. Step 12: Click the Select/Unselect All button ( Step 13: Click the Depenetrate auto button ( correction. Note: ) to select all the penetrations. ) to launch the automatic penetration

Step 14: Wait for HyperCrash to finish the correction process (this may take a few seconds). There are two options to find and to correct the penetrations in HyperCrash: you may use either a variable or a constant gap. The variable gap option (if Gap_interface = variable) searches and corrects the penetrations, taking the actual thicknesses of the plates into account (coming from the PID). The constant gap option (if you enter a value for Gap_interface) uses a (userdefined) fixed value (the value might be the gap of your interface, for instance) to search and correct the penetrations.

At the end of the automatic penetration correction, 0 penetrations remain: all the penetrations are automatically corrected by HyperCrash.

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Section 2: Check the Thicknesses


Step 1: In the Quality > Visu Thick. Sub-panel, enter 0.1 for the Min value. Step 2: Enter 5mm for the Max value. Step 3: Make sure to display and the Model and Click on Fit Model ( display the whole model in the Graphic Window. ) buttons to

Step 4: On the Visu Thick. Sub-panel, click the See/Update display button ( display the iso-thicknesses in the Graphic Window.

) to

Step 5: Click Close to close the Quality > Visu Thick. panel.

Section 3: Check Your Model with the ModelChecker


Step 1: From the Pull-down Menu Bar, click Quality, then ModelChecker.

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Step 2: HyperCrash displays a list of errors, warnings, and information about the model in the order of severity in the ModelChecker window. Step 3: Select the Loose nodes of springs error message and click the View only icon ( ) to display it in the Graphic Window.

). One node of the spring is highlighted in blue. Step 4: Click the Fit Model button ( This node is not connected to anything.

Step 5: In the ModelChecker panel, right-click the Correction button ( Modify Springs.

) and select

Step 6: HyperCrash opens the Mesh Editing > Modify > Element > 1D sub-panel. Click the Pick element(s) to select element(s) in list button ( ) and, in the Graphic

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Window, pick the spring to highlight it in red. Validate the selection with Yes in the Dialog Menu Bar. Step 7: Delete this unconnected spring by clicking the Delete selected element(s) button ) (you may have to enlarge the panel to see the Delete button). Confirm the ( deletion with Yes in the Dialog Menu Bar. Step 8: Click Close in the Mesh Editing > Modify > Element > 1D sub-panel. HyperCrash returns to the ModelChecker after having updated the list. Step 9: In the ModelChecker sub-window, select the Rbody Master on element(s) error message.

) and select Modify RBODY. HyperCrash Step 10: Right-click the Correction button ( opens the Mesh Editing > Modify > Rigid Body panel. Note: In the rigid body list, the green rigid bodies have a correct definition and the red ones have a bad definition. HyperCrash can automatically or semi-automatically correct the bad rigid bodies. A rigid body has a bad definition if: The master node is on an element. If there is y in the column under the icon the rigid body list, the corresponding rigid body is bad. One or more slave nodes belong to another rigid body If the number in the column under the icon is greater than 0, the corresponding rigid body is bad. in

The rigid body has just one or no slave nodes If the number in the column under the icon is less than or equal to 1 (1 or 0), the corresponding rigid body is bad.

In the same rigid body, the master node is also selected as slave. If there is y in the column under the icon , the corresponding rigid body is bad. to display

Step 11: In the rigid body list, select the first rigid body with an error and click it in the Graphic Window.

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This rigid body has only one slave node (one in the body is bad.

column). Therefore, the rigid

Step 12: Click the Delete selected rigid bodies button ( ) to remove this rigid body. Confirm the deletion with Yes in the Dialog Menu Bar. Step 13: Select the next rigid body with an error and click ( Window. ) to display it in the Graphic column),

The master node of this rigid body is on an element (y in the therefore, the rigid body is bad.

Step 14: In the rigid body list, right-click and select See Rbody Master on element(s) in the pop-up menu to display the connected element in the Graphic Window.

Step 15: Click Save to automatically correct the rigid body. The rigid body master node and the element node are disconnected. The rigid body master node is moved to the slave node center of gravity. The element node is included in the rigid body as a slave node. Step 16: Select the next rigid body with an error and click Window. to display it in the Graphic

One slave node of this rigid body belongs to another rigid body (1 in the column), therefore, the rigid body is bad. Step 17: In the rigid body list, click the right mouse button and select See slave nodes in other Rbodies to display in blue the multiple slave node in the Graphic Window.

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) in the Step 18: Click the Add/Remove nodes by picking selection button ( Selection sub-panel and, in the Graphic Window, pick the slave node to unselect it. Confirm the unselection with Yes. Step 19: Click Save in the rigid body panel. Step 20: Select the last rigid body with an error and click Window. to display it in the Graphic

The master node of this rigid body is also defined as slave for itself (y in the column), therefore, the rigid body is bad (incompatible kinematic condition). Step 21: Click Save in the rigid body page to automatically correct the rigid body. The master node is removed from the slave node list. Step 22: Click Close in the Rigid Body sub-panel to return to the ModelChecker panel. Step 23: Click Close in the ModelChecker panel to return to the main menu. ) and Fit Model ( Step 24: Click Display All ( the Graphic Window. ) buttons to display the whole model in

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Chapter 9: Replace Function

Chapter 9

Replace Function
The purpose of this chapter is to quickly replace the right door of the model with a new one. Following the steps in Chapter 2, Section.1, load the model called CHPT8_0000.rad. Step 1: In the Tree window, highlight the RIGHT DOOR assembly (in the DOORS assembly). Step 2: Click the right mouse button and, in the pop-up menu, select Replace, then RADIOSS. Confirm your choice for replacement clicking Yes in the Dialog Menu Bar.

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Step 3: In the 0000 .rad file to replace Part window, select the NEW_DOOR_0000.rad model and click OK. It may take a few seconds for HyperCrash to update the model. Note: HyperCrash automatically recreates: the connections (spotwelds and bolts) the interfaces. (Only the interfaces involving the whole replaced system are kept and regenerated on the new system). the added masses the boundary conditions the initial velocities the loads (imposed velocities and forces) the connected rigid bodies the connected 1-D elements

Step 4: In the Replace System window, the list of the features rebuilt by HyperCrash is displayed:

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1 added mass 1 initial velocity 5 rigid bodies 1 interface Step 5: Check that these features have been recreated well by navigating from the Pulldown Menu to the following menus and viewing the listed items in the Graphic Window: Select LoadCase, then Added Masses, then Modify Select LoadCase, then Contact Interfaces, then Create/Modify Select LoadCase, then Initial Velocities, then Modify Select Mesh Editing, then Rigid Body, then Modify have been rebuilt on the new right door.

Step 6: Click Close to close the Replace System panel and return to the main menu.

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Chapter 10: Time History Selection

Chapter 10

Time History Selection


Following the steps in Chapter 2, Section 1, load the model called CHPT9_0000.rad.

Section 1: TH Node Selection


Step 1: From the Pull-down Menu Bar, click Data History, then Node, then Create.

Step 2: In the Create > TH > Node panel, enter the name B-Pillar as shown in the following image and click Ok.

Step 3: In the Tree Window, highlight and display the part, B-PILLAR-INNER (in the Body in White Body assembly) and click the Isolate Tree Selections icon ( ). Step 4: Go back to the Data History > Node > Create panel and click the Pick nodes to add button ( ).

Step 5: In the Graphic Window, one node at the top of the B-Pillar and one at the bottom.

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Step 6: In the Dialog Menu Bar, click Yes to finish the selection. Step 7: When you finish the selection, the nodes are listed in the sub-window. Select the first one and click the See selected node icon to display it ( ).

Step 8: In the Node name field, enter B-Pillar_Upper and click Ok to change the node name (see following image). Step 9: Select and rename the second node to B-Pillar_Lower. Click Ok (see following image).

Step 10: Click Save and then Close to return to the main menu

Section 2: TH Section Creation


Step 1: From the Pull-down Menu Bar, click Data History, then Section, then Create. Step 2: In the Section sub-panel, enter the name LEFT_RAIL and click Ok (see following image).

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Step 3: In the Tree Window, highlight the parts LEFT RAIL 1, LEFT RAIL 2, and LEFT RAIL 3 (in the assembly Body in White Frames). Step 4: Click the Isolate Tree Selections button ( ).

Step 5: Go back to the Data History > Section > Create sub-panel and click the Add parts by box selection button ( ).

Step 6: Drag a box to select the front left rail parts. Step 7: For the Section plane normal, select the in X toggle as shown in the following image (default value). Step 8: Enter 3950 for the X Position value (see following image).

Step 9: Click the See selection button (

) to display the section.

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Step 10: Click Save and then Close to return to the main menu.

Section 3: TH Part Creation


Step 1: From the Pull-down Menu Bar, click Data History, then Part, then Create. Step 2: In the Part Create panel, enter the name TH-PART and click OK. Step 3: In the Tree Window, highlight the MODEL assembly. Step 4: Back in the Data History > Part Create panel click the add selected part of tree button ( ) to select all the parts.

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Step 5: Click Save and then Close to return to the main menu.

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Chapter 11: Clean the Model

Chapter 11

Clean the Model


The purpose of this chapter is to delete the unused objects in your model. Following the steps in Chapter 2, Section.1, load the model called CHPT10_0000.rad. Step 1: From the Pull-down Menu Bar, click Mesh Editing, then Clean. Step 2: In the Clean panel, select the All option (see following image).

Step 3: Click the Clean button and then click Close to return to the main window.

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Chapter 12: Final Steps

Chapter 12

Final Steps
Following the steps in Chapter 2, Section.1, load the model called CHPT11_0000.rad.

Section 1: Export the Model


Step 1: In the Pull-down Menu Bar, click File, then Export, then RADIOSS file 51.

Step 2: In the Write Block Format 100 RADIOSS file window that appears, enter the name CAR35_2 and click OK (see following image).

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Step 3: In the Header of Radioss file window that appears, click Save Model.

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Step 4: A window titled Write 0001.rad file, V100 window appears. In the Generalities tab, Title: field, enter the title OFFSET FRONT CRASH 35 mph. Enter all the parameters as shown in the following image, and click Write Engine File.

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Chapter 12: Final Steps

Section 2: Run the Starter for this Model


Step 1: From your computers start menu, open the Altair HyperWorks menu and select RADIOSS to open the RADIOSS Manager.

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Step 2: In the Input file: field of the RADIOSS Manager, enter the path and file name of the model (Car35_2_0000.rad). From the pull-down menu, choose Starter, and click Run. Review the .out file for ERRORS, WARNINGS, TIME STEP, and TOTAL MASS.

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Chapter 13: Dummy Positioner

Chapter 13

Dummy Positioner
The purpose of this chapter is to give you a basic overview of the tools available in the Safety module of HyperCrash. This module will show you how to position a dummy and generate a seatbelt. Note: Restrictions to Altair dummies in block format.

Section 1: Load the Dummy


Step 1: Open a new HyperCrash session, selecting an environment with the following units: kN_mm_ms_kg. Step 2: Load the model called SEAT_0000.rad (From the Pull-down menu, choose File, then Import, then RADIOSS File). Step 3: From the Pull-down Menu Bar, select Safety and click Dummy Positioner.

Step 4: In the Dummy Positioner panel, click the Dummy model list drop-down menu, and select New Dummy to open the DummyMng panel.

H305 Step 5: In the DummyMng panel, select the File tab and click the H250D15BD00 dummy (see following image).

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Step 6: Click Validate. Step 7: The DummyMng > Offset panel opens. Click OK to confirm the numbering of various entities in the dummy.

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Step 8: The merged dummy is highlighted in the Graphic Window. Click the Refresh button ( ) to return to a normal display.

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Section2: Position the Dummy


Step 1: Set the References Points. 1. Click the Ref points button (default). 2. Enter the following H point coordinates, pressing ENTER in each field, as shown in the following image: Hx = 2470 Hy = 351 Hz = 663 3. Enter the Ry angle: -15 degrees (see following image) and press ENTER to validate.

Step 2: Modify the dummy coordinates to obtain the correct position. Note: Use the View menu to modify the point of view. 1. To position the lower limbs, select the Lower limbs radio button. 2. In the Left leg section, select beta around y in the Delta pop-up menu.

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3. Click the Mouse moving button (

).

4. In the Graphic Window click a node of the left foot and drag the foot to the desired position. Then click Yes or press ENTER. If the position is correct, press ESC. 5. Click the Finish ( ) button.

6. For the right leg, you can directly enter the same value of the angle. In the Right leg section, select the beta around y in the Delta pop-up menu. 7. Enter the value and click the Finish button ( ) to validate.

Step 3: Repeat the same procedure to position the body and/or the upper limbs to obtain the final position.

Step 4: Click Close to close the Dummy Posit panel.

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Chapter 14: Seat Belt Generator

Chapter 14

Seat Belt Generator


Step 1: From the Pull-down Menu Bar, select Safety and click Belt Generator.

Step 2: In the field provided, enter the name of the belt, BELT1, and click OK (see following image).

Step 3: Click the

button to define the reference points. A new panel appears.

) to select the seat belt reference points Step 4: Use the Add nodes by picking button ( on the dummy (see the picture, following), validate with Yes, and click OK when finished.

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Step 5: Select the parts which have to be interfaced with the belt (upper torso) by using the Add/remove body parts by picking button ( press ENTER. ). When finished, click Yes or

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Step 6: Leave the default values for belt generation except the first node transversal direction: Gap = 4mm Belt width = 50mm Number of elements in length = 30 Number of elements in width = 3 Transversal direction at first node = X Transversal direction at last node = X Step 7: Click the Choose material in database button ( ).

Step 8: In the Material File selection window, choose the FABRIC and click OK to validate in the Dialog Menu Bar. Step 9: Click the Choose property in database button ( ).

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Step 10: In the Property File selection window, choose the Seat_Belt property and click OK to validate in the Dialog Menu Bar. Step 11: Click the See button to view the seat belt. Note: You can use the Options menu to adjust the interface between the torso and the belt (initial penetrations)

If the belt is not correct, redefine the reference points again.

Step 12: When the belt is correct, click Save to save it. Step 13: Repeat 0 to 0 to create a Lap Belt

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Appendix I: The M00file, a HyperCrash file

Appendix I

The M00 file, a HyperCrash file


Check the files generated by HyperCrash. You will find a _0000.rad file, a _0001.rad file and an M00 file. This last file is a HyperCrash specific file; it is not necessary for the RADIOSS computation. The M00 file contains the description of macro-objects which do not exist in RADIOSS input. It is used by HyperCrash only. If the _0000.rad file is named ROOTNAME_0000.rad, then the M00 will be named ROOTNAMEM00. The M00 file contains information such as spotwelds, bolt, hierarchy, dummy, etc. Examples Let us say that you have created some spotwelds using HyperCrash and have saved your model. When you re-read your model, the spotweld entities are recognized as such by HyperCrash only if the corresponding M00 file is present. Otherwise, HyperCrash will display springs and tied interfaces, not spotweld entities (unless you use the spotweld extraction proposed in the connections menu). Let us say that you have loaded and positioned a dummy using the dummy positioner and saved your model. If you later want to change the position of the dummy, HyperCrash will need to retrieve the dummys information from the M00 file; otherwise it will only display nodes and elements and not a dummy entity, and you will not be able to reposition your dummy.

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