TME195 Advanced Passive Safety Project 1 Headform to Hood Impact Analysis

Department of Applied Mechanics Division of Vehicle Safety CHALMERS UNIVERSITY OF TECHNOLOGY

April 2010

Project
This project is to be carried out in groups of two (maximum three) students. A written final report is required and the date to hand in this report is May 17th, 2010. Make sure to register your group on the separate list handed out in class. All groups should be ready to present their results during the session on May 17th, 2010. Please email your presentation to manuel.mendozavazquez@chalmers.se before 13:00 on May 17th, 2010.

Software
You can download and install LS PrePost on your own computer. It is also installed in the computer rooms at the M-building. The version that we will use is LS PrePost v2.4 and you can get it from http://www.lstc.com/lspp/. LS PrePost is a pre and postprocessor intended specifically for LS Dyna, which is the FE solver that we will use during this course. The LS Dyna solver is installed in the computer rooms at the M-building.

Sessions
There will be six supervised laboratory sessions. The dates and place for the supervised laboratory sessions are: DATE Monday Thursday Wednesday Monday Wednesday Monday TIME 15:15-17:00 08:00-09:45 13:15-15:00 10:00-11:45 13:15-15:00 10:00-11:45 ROOM MT11 HC105 MT9 MT9 MT9 MT9

12-apr 15-apr 21-apr 26-apr 05-may 10-may

Description
In this project you will simulate and analyze the impact of a headform against a passenger car hood. This passenger car is under development and you are in charge of the pedestrian safety. Among all tests that the car shall pass before it reaches the public, you are in charge of the headformhood impact test simulations. Assume that the experience in the company has shown that the results from headform model and the head model required by the regulations are equivalent.

The project is divided in the following four tasks: 1) Generate the input file: You will get the necessary models to perform this impact analysis as in Figure 1. You will need to define initial and boundary conditions as well as contacts and set the models in an adequate position. The simulations will be performed using two different initial positions. The first position is described in this document and will be referred as central position. The second initial position will be defined by you.

Figure 1. Headform and hood models. 2) Analyze the results: Check the simulations regarding numerical problems (i.e. energy balance, hourglass, added mass for mass scaling, negative volumes, etc). Calculate the HIC36 (Head Injury Criterion 36 ms) and HIC15 for the headform in both positions. 3) Implement design changes: In this section you will focus on the headform that impacts the hood at the central position. In case that the HIC36 value is larger than 1000, you will need to implement design changes to the model, perform the analysis and calculate the HIC36 until it reaches a value under 1000. Some constraints for the design changes are: The total weight of the hood should not exceed: 19 kg. The hood material is steel. You can vary the thickness of the hood metal sheets by 0.1 mm. Hint: You can change the thickness of the metal sheets by modifying their *SECTION card. Neither the body in white (BIW) nor the engine can be modified in any way. Both major hood pieces have to be glued as depicted in Figure 2. The choices to maintain those pieces bonded are either a structural epoxy adhesive or an anti-flutter. The available epoxy adhesives have a Youngs modulus between 10000 and 15000 MPa. While the anti-flutter modulus is in the range 1 to 100 MPa. Hint: Both adhesives have the same geometry and mechanical properties except for the Youngs modulus defined in the *MAT_SPOTWELD card.

Choose the design that generates a HIC36 value under 1000 for the central position and test it for the position that you defined in Task 1. What happened to the HIC36 value? Why?

Figure 2. The spots indicate the glued areas. 4) Suggest countermeasures: Which modifications should be included in the next generation of this car to comply with the required HIC36 value? Discuss some concepts to improve the pedestrian safety regarding head to hood impacts. Do you consider the headform to be biofidelic? Is HIC36 a criterion that can predict most of the real life pedestrian head injuries?

Task 1: Generate the input file

-Get the following file from the course webpage: headform_hood_01_initial.k -Open the input file using LSPrePost Which units are used in the model? -Save the file. Note that LS-DYNA will write the results in the same location as the input file and that all output files will have the same default names. Therefore it is advisable to store and run each input file in different directories. -Use the Translt and Rotate functions under Page 2 to move the headform so that the coordinates of the accelerometer (Node ID = 1) are: (-772, 0, 1014.65) and the headform is looking down as in Figure 3. Repeat this procedure to create a second file and place the headform in a position of your choice. Hint: Use Page 1 Ident Node to get node 1 coordinates. Do not forget to select all the nodes in the headform (total: 26932 nodes)

Figure 3. Central position

-Define a part set that contains the headform parts involved in the contact with the hood. Page 5SetD - Create - *SET_PART SetID = 1 Type a Title such as headform_contact Pick the headform parts involved in the contact. -Define the contact between the headform and the hood. Page 3 - *Contact AUTOMATIC_SURFACE_TO_SURFACE Edit NewID Select the slave and master segments SSID corresponds to the ID of the PART set that you created in the previous step. All other values can be taken from Figure 4.

Figure 4. Contact card for the contact between the headform and the hood. -Define a node set containing all the headform nodes; this will be used to define the initial velocity of the headform. Page 5SetD - Create - *SET_NODE Pick nodes from screen. Hint: Be sure to select all the nodes in the headform (total: 26932) -Define the initial velocity for the headform. Page 5 IniVel Create Select the Node set that you created previously Apply 40 km/h to all nodes on the headform. Hint: Check the units and the direction of the initial velocity - Look in the constraints card. Page 3 - *Cnstrnd NODAL_RIGID_BODY_SPC Edit What is the meaning of CMO, CON1 and CON2 in this card? How is the hood constrained? Where and which degrees of freedom are constrained?

-Identify the requested results. Page 3 - *Dbase ASCII Option Edit. Look in LS Dyna manual for the meaning of the selected output files. Are all the necessary output files requested? -Check control cards. Page 3 - *Control Pick the card of interest and press Edit. How long is the simulation time, check the TERMINATION card? What is the time step? Is mass scaling used? -Submit your input file to the solver Open LS-DYNA Manager. Press Solver. Press Start LS-DYNA Analysis. Select your input file and press RUN. Hint: You can open the result files even if the termination time is not yet reached. In this way you can monitor your simulation.

Task 2: Analyze the results

-Open the d3plot file to see the animated result. Animate it and see if the results are as expected. -Open the binout file Page 2 Binout Load pick your file Open Select the file from the Open files list at this point you should get a list with the output files that you requested (i.e. glstat, matsum, nodout, rbdout) -Check the energy balance from the glstat file. Plot the internal, kinetic, total and hourglass. How much mass was added? Which was the time step? -From the matsum file, identify the material with highest hourglass energy. -From the nodout file calculate the HIC 36 for the headform. Select 1 from the Nodal branch Check the Hic/Csi option Select the desired HIC Check the Apply pre-filter Filter the acceleration with SAE1000 and choose the Grav.Con that is consistent with the units used in this model as in Figure 5. Is there a difference in the value if you calculate HIC15 instead? How is HIC defined?

Figure 5. HIC calculation in LS PrePost

Task 3: Implement design changes

Take in consideration the listed design constraints in order to get a HIC36 value lower than 1000 for the central position. Use the design proposal that generated a HIC36 value under 1000 to calculate the HIC36 value for the initial position that you proposed in Task 1. Hint: You may need to modify the simulation time on the card *CONTROL_TERMINATION

Task 4: Suggest countermeasures

Discuss some concepts to improve the pedestrian safety regarding head to hood impacts. Do you consider the headform to be biofidelic? Is HIC36 a criterion that can predict most of the real life pedestrian head injuries?

Support:
LS PrePost : http://www.lstc.com/lspp/ LS Dyna Documentation: Open the LS-DYNA Manager and choose the desired manual under the MANUALS menu. Manuel Mendoza Vzquez: manuel.mendoza-vazquez@chalmers.se