Event : JAPAN LS-DYNA Users Week 2007

JAPAN LS-DYNA Users Week 2007

Users Conference Program

Tuesday, October 30 / Wednesday, October 31

Abstract

10/30 10:30-11:30 Keynote Speech

Computational Engineering with Numerical Simulations - What have we learned from 30 years' CFD Research ?
Prof.Kozo Fujii, Japan Aerospace Exploration Agency

computational fluid dynamics (CFD) has come to a certain stage where many industries use this technology in their product design. A lot of free and commercial software became available, and with the help of computer hardware development. even a small laboratory in universities can now conduct fluid dynamic research using CFD as a tool. With such spread of CFD technologies, people tend to forget importance of numerical algorithms, solution accuracy, uncertainly and other factors of computer simulations they are running. In this plenary talk, clues to overcome problems in the future simulations will be discussed based on the 30 years' speaker's CFD research. Recent trends of CFD methods, for example, of direct simulations of acoustic emissions from high-speed flows will also be addressed in the presentation.

Rupture modeling of Spot Weld Suitable for Vehicle Development Process Mr.Koshi Kumagai, Toyota Motor Corporation
10/30 11:30-12:00 General Session(1)
A spot rupture model using beam element and mesh free connection, which can simulate both nugget pull out and nugget fractuer mode of spot weld repture, has been developed. Full vehicle level of FE analysis was conducted to confirm the prediction accuracy of develped spot rupture model. The results show that spot rupture locations closely correlate with the actual crash test.

10/30 14:00-14:50 Plastic CAE Session (1)

Design of toughness by nonlinear CAE for the molding of plastic
Prof.Masaru Ishikawa, Yamagata University

The concept of the design of strength for the structure of plastic was examined on the base of the mechanics of plasticity. It was pointed out that the characteristics of the plastic deformation of polymer are both the strong softening after initial yielding and the orientation hardening with the increase of plastic strain. Therefore, for the design of strength with the high precision, a convenient technique of the estimation of nonlinear constitutive equation was required

10/30 14:50-15:40 Plastic CAE Session (1)

Advanced Methods for the Characterization on highly non-linear Materials for Crash Applications
Dr.Stefan Hiermaier, Fraunhofer, Ernst-Mach-Institute

Predictive capability of numerical methods in computational mechanics means the ability to predict structural response under varying loading conditions, change of geometries and variations in boundary conditions without adaptation of material parameters. Only with that capability approved, numerical simulation can be treated as a useful tool in engineering design.
In order to meet the mentioned demanding to a predictive tool, the mathematical model describing the material behaviour has to cover all relevant characteristics in the physical behaviour of the modelled material. Additionally, the free parameters in the model need to be derived from precise material tests under well defined stress and strain states. The latter, a precisely known combination of stresses and strains in the sample, is what distinguishes a material test from a component or validation test. Both types of tests are useful, the first for parameter derivation, the latter for validation.
Therefore, it is of primary importance for material characterization to guarantee the assumed stress and strain states in a test set-up or to take changes into consideration if necessary. The more complex the material behaviour and the more dynamic the loading situation, the harder it gets to guarantee these demands. That is why material tests under high strain rate conditions need additional attention. Wave propagation effects cause transient stress-strain states.
The following specific topics will be covered in the presentation:

Local measurement of strain in quasi-static and dynamic material tests to derive local stress-strain data.
non-constant volume under plastic deformation of some polymers. Test set-ups and enhanced qualities of multi-directional optical strain measurement with regard to volume change will be proposed along with the related additional modelling efforts.
characterization of low impedance materials, e.g. rubber or foam materials, under high strain rates in the range of 102 [s-1] to 103 [s-1] will be introduced as an example to identify the admissible phases in the testing.
Numerical simulation in parallel to tests for better interpretation and understanding of the related physics.

Experimental and numerical examples will be given on basis of recent investigations performed at Ernst-Mach-Institute.

10/30 16:05-16:30 Introduction of advanced technology with the large scale computer

Utility business model GridASP - Case studies in manufacturing industry -
Dr.Satoshi Itoh, National Institute of Advanced Industrial Science and Technology

AIST aims to spread the utility of IT systems using Grid Technologies. GridASP is the business model that provides computers and software as an utility for technical computing. We are developing the software GridASP Toolkit which realizes the business model GridASP. We are collaborating with several private companies in order to do proof-of-concept experiments, and preparing to provide the utility services. In my talk, I would like to introduce benefits of GridASP and case studies of GridASP in manufacturing industry. Moreover, I will explain available services for LS-DYNA users.

10/30 16:30-17:00 Introduction of advanced technology with the large scale computer

Micro-Macro Interlocked Simulation of Friction Dynamics
Dr.Shigenobu Hirose, JAMSTEC

In macroscopic elastic dynamics simulations, frictional force is usually computed using an empirical law (Amonton’s law) since no physics that describes friction is contained in elastic dynamics. We are developing a micro-macro interlocked simulation scheme for friction dynamics where frictional force in macroscopic simulation is physically determined by microscopic atomistic simulation in the framework of the "patch dynamics".

10/30 17:00-17:30 Introduction of advanced technology with the large scale computer

Large-scale Parallel Simulation of 3-D FEM Model of With Rein-forced Concrete buildings
Mr.Yasunori Mizushima, Osaka University

In order to prevent urban disaster, it is very important to simulate the actual dynamic behaviors of building structures suffering big earthquake. For this aim, usually, buildings are considered as simple models in which mass and spring are connected in series. However, these simple models are not enough to evaluate actual behavior of building on earthquake. In this report, more accurate models are used. Concrete and steel bar are modeled by cubic solid elements and by linear elements, respectively. Standard mesh sizes of those elements are 10cm. In this simulation, concrete piles and surrounding ground are also modeled by similar way. 'Earth Simulator' was used for this large-scale simulation.

Plastic Material Model in LS-DYNA Mr.Paul Du Bois, Hermes Engineering NV
10/31 9:30-9:55 Plastic CAE Session (2)
TBA

Estimation of Residual Stress and Shrinkage of a Molded Product using the 3-D Flow-Structural Coupling Analysis Method for Thermosets Dr.Junichi Saeki, Hitachi, Ltd.,
10/31 9:55-10:20 Plastic CAE Session (2)
TBA

Challenging of our Plastic Modeling in JRI Solutions, Ltd. - Report of Our Plastic Seminar - Mr.Kimihiro Hayashi, JRI Solutions, Ltd.
10/31 10:20-10:45 Plastic CAE Session (2)
TBA

The potential of coordination of LS-DYNA and J-OCTA Dr.Taku Ozawa, JRI Solutions, Ltd.
10/31 11:10-11:35 Plastic CAE Session (2)
We introduce the potential of coordination of LS-DYNA and J-OCTA, the software which can evaluate molecular and material properties of the desired polymer from the microscopic and macroscopic points of view.

Computer Simulation for Polymer Material Design Dr.Takeshi Aoyagi, Asahi Kasei Corporation
10/31 11:35-12:00 Plastic CAE Session (3)
We will present the effective application of computer simulation, especially molecular modeling and mesoscale simulation for the development of polymer materials in industry. Some examples, which have been studied in Asahi Kasei Corporation, will be introduced.

10/31 14:00-14:45 Keynote Speech

Will the Bottle Leak? The Modeling & Simulation of Everyday Products
Mr.Thomas Lange, The Procter & Gamble Company

Enabled by high performance computing software and hardware, modeling & simulation (M&S) has greatly accelerated the pace of innovation for planes, trains & automobiles. Often behind the scenes, this same approach is helping P&G to innovate everyday products. Over 3 billion times a day, P&G is making everyday life a little better?in everything from better diapers for babies to cleaning clothes, from washing hair to shaving. With P&G making/ selling billions of things each day, we will explore some of the ‘surprising’ technical challenges this presents. We will review a brief series of examples including a study on the aerodynamics of Pringles?, a Liquid Bottle Drop Test, and other multi-physics problems (FSI Fluid-structure interactions). As we look to the future, how will we use the growth of computing hardware capacity? What will we solve tomorrow?

JRI-Solutions' Products Development Plan and Services Mr.Kimihiro Hayashi, JRI Solutions, Ltd.
10/31 14:45-15:30 General Session(2)
JRI-Solutions provides the structural simulation products such as LS-DYNA, JSTAMP/NV, and Pre/Post products such as JVISION ,ARUP Software. We believe that those products can bring the best solution for the users. In this paper, we introduce the aim of the development and services of each product from the standpoint of providing the solutions that satisfy the users' needs.

New Developments in LS-DYNA Dr.John O. Hallquist, Livermore Software Technology Corporation(LSTC)
10/31 15:30-16:45 Invited Lecture
Based on the recent trend in CAE and requests from the global users, LSTC's goal for software development and project for developing LS-DYNA and other related software will be presented in association with the key terms of multi-physics, multi-stage, and multi-processing. Furthermore, features and applications of the latest version of LS-DYNA currently being developed will be presented.

TBA Mr.Naoki Yanagi, AISIN SEIKI Co.,Ltd.
10/30 14:00-14:25 Production Engineering Session (1)
TBA

10/30 14:25-14:50 Production Engineering Session (1)

Deformation in Spinning Forming of Welded Steel Pipe （FEM Simulation of Spinning Forming）
Mr.Akihiro Ando, Nisshin Steel Co.,Ltd.

The material deformation in spinning forming of welded pipe of ferritic stainless steel was investigated by using FEM simulation. The simulated results, such as deformed shapes, deformation behavier and thickness distributions in spinning forming, are in good agreement with the experimental results. This FEM analysis technique makes it possible to understand the mechanism of the material deformation in spinning forming and to provide the suitable spinning conditions.

Square cup forming of partially softened aluminum alloy sheets. Mr.Takeshi Nishiwaki, Nagoya Municipal Industrial Research Institute
10/30 14:50-15:15 Production Engineering Session (1)
The effect on square cup formability of partially softening was investigated for high strength aluminum alloy sheets. The part of the 6061-T6 circular blank was locally heated to be softened using heated metal dies. The effect of partially softening on the formability and the optimal softened region to obtain the best formability can be predicted by the numerical analysis using LS-DYNA.

Effects of Forming Conditions to Distortion of Curved Hat-Channel Panel (Investigation of Distortion Mechanism using Forming Simulation) Mr.Toshiya Suzuki, Sumitomo Metal Industries, Ltd.
10/30 15:15-15:40 Production Engineering Session (1)
TBA

The Application of LS-DYNA for Roof Buckling Analisys Under Snow Load Mr.Noriyo Ichinose, JRI Solutions, Ltd.
10/30 16:05-16:30 Automotive Engineering Session (2)
Generally, an implicit FEM solver is used for roof buckling analysis. However the implicit method has divergence problems when buckling occurs. LS-DYNA has a function that switches automatically from implicit method to explicit. This function is very useful for the divergence problem of implicit solvers. This paper shows an application of LS-DYNA for roof buckling analysis.

10/30 16:30-17:20 Automotive Engineering Session (2)

Current and Relevant Knowledge for Automotive Safety Engineers: Highlights from the 2007 German SafetyUpdate
Mr.Rainer Hoffmann, carhs.training GmbH

SafetyUpDate is a new training concept, pioneered by carhs.training GmbH in 2003. Since its inception it has attracted every year 200 German automotive safety experts. The SafetyUpDate aims at delivering the latest knowledge and developments in automotive safety engineering to the participants. It covers requirements with the latest findings in biomechanics and accident research as well as news in legal and NCAP compliance testing. Most recent development strategies are discussed for frontal and side impact, pedestrian safety and active safety applications. The systematic view is completed by an update on the latest development in safety testing and simulation technology. The in-depth presentations at the SafetyUpDate are given by the most renowned experts from academics, industry and government organizations.The highlights presentation will give a condensed overview on the SafetyUpDate held in April 2007 in Aschaffenburg, Germany.

Computer simulation for motorcycle rider-motion and injury evaluation in collision Mr.Hideo Namiki Honda R&D Co.,Ltd. Motorcycle R&D Center
10/30 17:20-17:45 Automotive Engineering Session (2)
Honda has been developing computer simulation technology, capable to predict the injury levels, in tests from the start of a collision until the point where the dummy strikes the ground. Using this technique,　performance and effectiveness of an airbag system for a GL1800 in 200 impact configurations and 400 cases specified in ISO/CD13232 was evaluated by using the computer simulation.

10/31 9:30-9:55 Production Engineering Session (2)

Forming Limit Prediction of Sheet Metals by Combination of Ductile Fracture Criterion and Finite Element Simulation
Prof.Hirohiko Takuda, Kyoto University

The authors have recently proposed an approach to predict the forming limit by introducing criteria for ductile fracture into finite element simulation of sheet metal forming processes. In this study, first, it is found that the criterion by Cockcroft and Latham is most suitable for high-strength steel sheets. Next, as fundamental press forming processes, deep drawing, stretch forming and bore expanding of high-strength steel sheets are simulated by LS-DYNA combined with the ductile fracture. The comparison with the experimental results demonstrates that the fracture initiation site and the forming limit are successfully predicted by the present approach.

10/31 9:55-10:20 Production Engineering Session (2)

Basic research for impact characteristic about new core structure
Prof.Ichirou Hagiwara, Mr.Kouta Takeda, Tokyo Institute of Technology

Today, we need more lightweight and more rigid member, because of environment concern. Especially, the measure of this concern about car is demanded. So we notice light and rigid panel, which would substitute for car door panel and all that. This panel is derived from the theory that how we can fill plane with a certain geometrical figure. Truss Core Panel is a one of them and subject we research. We evaluate its bending characteristic through the dynamic simulation.

10/31 10:20-10:45 Production Engineering Session (2)

Shock protection damper designning by using CAE
Mr.Eiichi Hattori, Yamauchi Corp

Cam corder media has been changing from Tape to DVD and HDD. Especially, HDD Cam corder has a weak point that easy to be spoiled by shock. Therefore it is equipecl with shock protection dampers. The way of evaluation of them is free drop test. However, that kind of test has a problem that low reliability and high cost.That is why demand of CAE simulation by damper maker becomes higher. In this paper, we report our examples of it.

Dynamic FSI Analysis of shock absorber valves Mr.Shozo Tokumitsu, KYB Corporation
10/31 11:10-11:35 Automotive Engineering Session (3)
To improve the shock absorber response , linear damper force characteristic is requested in a low-speed region . The characteristics difference between same diameter valves and different diameter valves , was clarified using ls-dyna FSI .

10/31 11:35-12:00 Automotive Engineering Session (3)

An Approach Of Robust Design Optimization On Side Impact Simulation
Mr.Masahiro Awano, Mitsubishi Motors Corporation

It is well known that the variation of analysis parameters is a big issue for crash simulation of safety performance on occupant protection using FEM. In this work, an approach of Design For Six Sigma using approximation model is proposed to take account of the variation on material and dummy position into the robust design optimization. As a result of this work, both of the mean value and deviation of injury index are reduced, and the sigma level of objective index is increased. Finally the effectiveness is confirmed by comparing results of robust analysis using Design of Experiment at initial design and robust design point.

10/30 14:00-14:50 Automotive Engineering Session (1)

15 Years Dummy Model Development within the the German Association
of Automotive Research (FAT)
Mr.Ulrich Franz, DYNAmore GmbH

Within the FAT all major German automotive companies join parts of their research activities. Therefor the FAT initiates many research projects of common interests. One project is to develop finite element models for side impact simulations. The group started 15 years ago to develop models of the USSID and Eurosid-1. Later other models followed. The paper summarizes the activities during the projects and outlines the tests and methods applied to develop the models.

10/31 9:30-9:55 New Technologies Session(1)

Development of the Fracture Prediction Model of Spot Weld, and Application of the Model to Crash Simulation of Real Full Vehicle
Dr.Hiroshi Yoshida, Nippon steel corporation

In order to examine the compatibility of　improvement of crashworthiness with　weight-saving of automobiles by using high strength steel, we have established the new prediction model of the fracture strength of spot weld in automobile parts. By using of this model, we can predict exact crush mode and absorbed energy of the crash parts with spot-weld fracture. Therefore, we can simulate optimum design of the spot weld of the automobile parts.
It was modified that our model of stress concentration between the nugget of spot weld and the specimen could be applied for respective Ultra High Strength Steel (UHSS). We developed fracture prediction system based on this model in FEM for crash analysis. We tried to apply this system to crash simulation of the real full vehicle. It was confirmed that by using this system, maximum deformation of the vehicle body agreed with that of the experimental result. Furthermore, we could easily design the nugget diameter and the location of spot weld to prevent from crashworthiness reduction due to fracture of spot welding points.

10/31 9:55-10:20 New Technologies Session(1)

Stress analysis of artificial joints under dynamic motions using LS-DYNA
Dr.Mitsugu Todo, Kyushu University

Artificial knee and hip joints used for injured articulations of lower limbs are usually subjected to severe stress conditions. Furthermore, these artificial joints are used in several kinds of complex motions including flexion and rotation. Therefore, detailed 3D models need to be developed and dynamic analysis has to be conducted under real motions with proper boundary conditions.In this presentation, 3D FEA modeling of artificial knee and hip joints are presented first. Failure and dislocation analyses of artificial hip joints and stress analysis of artificial knee joints under complex motions performed by using LS-DYNA are summarized, and the relationships between the analytical results and the orthopedic problems are presented.

10/31 10:20-10:45 New Technologies Session(1)

Development of child FE model and its application to CRS impacts
Dr.Koji Mizuno, Nagoya University

To investigate child responses in impacts using a child restraint system (CRS), a three-year-old child FE model was developed. Each body was scaled from an adult FE model, and anatomies of child pelvis and head were considered. The responses were compared with a Hybrid III FE model in impacts, and global kinematics of both models differed due to the spine rigidity. In real-world, misuses of CRS are frequently observed. With seat belt slack, the injury parameters became high, which had a relation with ride down efficiency. At present, side impact analyses are also conducted, and to evaluate the performance of various CRS types, a 6-month infant model is being developed.

10/31 11:10-11:35 New Technologies Session(2)

Current State of High-Velocity Tensile Testing Method
Dr.Masaaki Itabashi, Tokyo University of Science, Suwa

The speed of high velocity tensile tests is typically one million times higher than that of the ordinary quasi-static tensile tests. For the former test, convenient textbooks have not been published yet. However, product design with dynamic mechanical properties is now attractive for engineers. According to such a demand from car and steel industry, several high velocity tensile test methods will be standardized, as ISO standard(s). This standardization itself will take a couple of years, or more. At this opportunity, features of each testing method and typical experimental results will be introduced to beginners of impact engineering.

10/31 11:35-12:00 New Technologies Session(2)

Surging Analysis of a Hydraulic Engine Mount
-An Explicit Approach for Frequency Response Analysis in LS-DYN -
Mr.Mitsuhiro Takayanagi Tokai Rubber Industries, Ltd.

Recently, various characteristics have come to be demanded from engine mounts as the NVH capabilities of vehicles improve. Because of their high capabilities for these requirements, hydraulic engine mounts are becoming widely adopted. However, frequency response analysis is difficult in a general solver because the hydraulic engine mount exhibits nonlinear behavior such as nonlinearities of the rubber material and the interaction of rubber and liquid. In this paper, an approach using LS-DYNA's explicit method is proposed for frequency response analysis.

10/30 14:00-14:50 Software and Programing(1)

An overview of New Features in LS-OPT
Dr.Nielen Stander, Livermore Software Technology Corporation (LSTC)

This paper summarizes the development status of LS-OPT Version 3.3 and focuses mainly on the following new features. (1) Radial Basis Function Networks used as surrogate design models, (2) Multi-objective Optimization, (3) Metamodel-based Multi-objective optimization, (4) User-defined metamodeling and (5) User-defined queuing. A multidisciplinary vehicle crash/vibration example is presented to illustrate the application of RBFN’s as well as the automatic creation of a Pareto optimal front using the Multi-objective evolutionary algorithm NS-GA II..

10/30 14:50-15:40 Software and Programing(1)

Developments in occupant and seat modeling with Primer 9.3
Mr.Richard Sturt, ARUP

There is constant pressure to reduce the time needed to process design data into crash results (mesh, assemble, create different crash cases, check, run, post-process). The meshing step has been reduced by batch meshing technology, and progress has been made in several other areas such as automatic post-processing. Attention is now turning to the remaining bottlenecks, which include occupant and seat positioning. These steps require careful manual work and cannot currently be automated. The problem is magnified by the large number of seat position/dummy combinations.Primer Version 9.3 solves these problems by providing fast methods of dummy positioning, seat positioning, seat foam compression, and belt fitting. The paper gives a brief overview of capabilities available in Primer 9.3.

New function of JSTAMP/NV V2.0 and the functions that will be equipped in the near future Mr.Nobuhiko Sugitomo, JRI Solutions, Ltd.
10/30 16:05-16:30 Software and Programing(2)
TBA

The next version of JVISION Mr.Toshiki Moritoh, JRI Solutions, Ltd.
10/30 16:30-16:55 Software and Programing(2)
We introduce the functions of the next version of JVISION.

10/30 16:55-17:20 Software and Programing(2)

TEC| Bench- Virtual Benchmarking; comparing products with CAE methods
Mr.Jurgen Veith, TECOSIM GmbH

"Virtual Product Development" has already been established completely within the automotive industry today and the processes of development can no longer be imagined without it. This has led, not only to clearly abridged product development times and to considerable cost savings in the development cycle, but also to a product variety which has never yet existed. Every manufacturer occupies or devises new product niches at increasingly shorter interval periods, in order to serve these and to generate new revenue turnovers through the new demand.
The advantages of the virtual development are basically the following:

Better understanding of the product through a greater variety of information
Predictability of the product behaviour under the most diverse conditions
Knowledge-based, instead of experience-based, product development
Reproducibility
Improved product maturity with the market launch
Drastic reduction of costs and resources

A comparison with the competitive products is still always carried out, however, on the basis of the hardware and the real product. This has all associated disadvantages, because the advantages of the virtual product development remain unused.
The now well established CAE process of, " TEC|BENCH™" TECOSIM GmbH, deals exactly with this point. It supplies the customer with virtual information about the competitive products, which provide him with a decisive knowledge margin over the daily competition. With these FEM models, LS Dyna was used to perform virtual benchmarking analysis.

10/31 9:30-9:55 Software and Programing(3)

A Study of Failure in RC Panels to Underwater Explosion Loadings by Numerical Simulation
Mr.Hirofumi Hoshina, TERRABYTE Co., Ltd.

To evaluate the strength of reinforced concrete (RC) panels by the underwater explosion (UNDEX), the fluid-structure interaction (FSI) analysis by LS-DYNA were carried out. First of all, the results of analysis for only the underwater explosion were examined and the validity of the models is verified with the experimental data of the literatures. Generally the blast loading in the water is more powerful than in the air. The results from the analysis of RC panels by UNDEX are presented about the first impact load and the bubble pulsations load of UNDEX, and RC panels are seriously damaged in comparison with results in the air those were studied by authors. The effectiveness of FSI analysis by UNDEX is demonstrated using some practical structures.

Application of non-linear analysis by explicit and implicit method Mr.Satoshi Ishikawa, Mechanical Design & Analysis Corporation
10/31 9:55-10:20 Software and Programing(3)
TBA

10/31 10:20-10:45 Software and Programing(3)

Considerations on Detailing Dummy Models Adequately.
Mr.Ulrich Franz, DYNAmore GmbH

The demands on predictability of dummy models increase steadily. From numerical mathematics is known that mesh refinements lead to more accurate solutions. The paper describes that a simple mesh refinement does not necessarily gives better results in occupant analysis. Therefore, the previously by the authors (FAT) developed models of the ES-2 and the BioRID II and the corresponding test database is used to investigate possibilities to increase predictability even more. The presented work has been performed to enhance the guidelines for the current development of the WorldSID 50th model together with the German Automotive Industry.

10/31 11:10-11:35 Software and Programing(4)

Data Compression for LS-DYNA and its impact on Robust Design
Mr.Clemens-August Thole, Fraunhofer Institute for algorithms and scientific computing (SCAI)

The usage of simulation as part of the automotive design process has increased the demand for archiving simulation results. Intensive collaboration during the development process requires the fast exchange of simulation results. Compression of simulation results reduces the size of archives and the time for data transfers. Like compression of video streams and pictures, the effective compression of simulation results requires specific tools which exploit the specific data structures of LS-DYNA3D simulation results and allow for a reduced precision of the results. FEMZIP is especially designed for the compression of crash simulation results and achieves a reduction by factor of 7 for reasonable precision requirements. The reduction of d3plot files allows seamless comparison of sets of simulation results in detail. Analysis of these sets of simulation results may lead to the discovery of reasons for the instability of simulation results and results in more stable models. The technology behind data compression and analysis for robust design is presented and concrete examples are studied.

10/31 11:35-12:00 Software and Programing(4)

Evaluation of New Finite Element Model for IIHS Side Impact Barrier-1st Format
Mr.Mehrdad Asadi, Cellbond Composites Ltd.

The IIHS (Insurance Institute for Highway Safety) MDB was developed by Cellbond in 2001 in conjunction with the institute. This barrier is used by the IIHS in their side impact tests and the shape is designed to represent the front end geometry of a typical SUV or pickup. The impactor consists of two different sized aluminium honeycomb blocks partially covered in aluminium sheets. This barrier has been investigated to produce an advanced FE model while experimental Flat-Wall and Solid-Pole test results are used to evaluate accuracy of developed model. The explicit LS Dyna 3D was used to analyze the model, and validated against number of static compressive tests performed at different angles to characterize Yielding aluminum honeycomb parts and corresponding Material Card data. A strain-rate scale factor curve is also defined to convert static test results into suitable data in honeycomb material card during the analysis procedure. Adhesive properties are obtained using Climbing Drum, T-Peel, Tensile and Plate Shear test results. The dynamic analysis was validated by a Flat-Wall test which represents the crush performance of IIHS barrier. This was mounted on a moving trolley that was tested at speed of 25 Km/h. In Pole test, the IIHS barrier is subjected to a symmetric crush with a rigid vertical pole in which test speed is 25 Km/h. The Final comparison on overall results represents a good correlation between test data and CAE results on both Flat-Wall and Pole tests.

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