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Crashworthiness Simulation using LS-DYNA

With Paul Du Bois

Duration: 2 or 4 Days

Note; this course is suitable for LS-DYNA users with at least 6 months experience of using the code or alternatively have already attended the LS-DYNA introductory course.

This course can be run as a 2-day course or a 4-day course. Please see the timing schedule below for details of what is covered each day.

This is an advanced course and applies to engineers which have experience in application of explicit programs or which bring along experience from the field of dynamic and nonlinear calculation with implicit programs. The aim of the course is to show how to perform a crashworthiness simulation in the automobile industry using LS-DYNA, whereby the presented methods are transferable to other kinds of crashworthiness simulations (rail vehicles, components of vehicles, airplanes, vans, etc.).

As participants of this course we expect new fellow employees from the department of crash simulation of a car manufacturer, new fellow employees of suppliers in automobile industry (suppliers of components, engineering companies) or users in related industrial sectors.

Each crashworthiness simulation is a compromise between profitability and accuracy. At the moment there is no kind of a guideline for modelling and calculating crash. Therefore the user has to be aware of advantages and disadvantages of different kinds of modelling procedures depending on the purpose of the simulation. Particularly the aim of the course is to show how to perform an accurate and reliable crashworthiness simulation by thorough modelling and further understanding of the procedure.

Content:

  • introduction to crash simulation using LS-DYNA, history, possibilities, technical limits, accuracy and reliability problems, future developments
  • modelling techniques for parts of car bodies: mesh convergence, mesh-outlay, element quality, flanges and weld spots, contacts, required mesh density as well as mesh quality using different shell elements and integration rules (examples for motor and rail vehicles)
  • modelling of connections : spotwelds , bolts, screws
  • modelling techniques for components consisting of other materials than steel: motion of motor, tires, bolts, rubber bushings, etc.
  • Selection and description of suitable material models in crashworthiness simulation for soft foams (chair cushions), EA-Foams, rubber and polymeric materials as well as steel panels
  • component models in LS-DYNA
  • Quality control of models as well as analysis and evaluation of the results

Timing schedule:

Day 1:

  • overview of industrial applications of crash/impact analysis
  • state-of-the-art vehicle modelling
  • time-step control in LS-DYNA
  • numerical damping and numerical noise

Day 2:

  • shell elements and hourglass control (*)
  • contact algorithms

Day 3:

  • material models for metals (*)
  • characterisation of metals
  • material models for plastics (*)
  • characterisation of plastics (*)

Day 4:

  • component analysis with LS-DYNA (*)
  • quality assurance of numerical models (*)
  • quasi-static analysis with LS-DYNA (*)

(*) : omitted in the 2-day version of the course

Due to the relationship among usually used explicit programs in industry, this course is also suitable for users of other programs. The course instructor is an expert in crashworthiness simulation and is working for several car manufacturers using different FE-codes worldwide. He is also an excellent and popular teacher.

Instructor:

Paul du Bois has worked as an independent consultant since 1987 and mainly does large scale industrial applications of finite element techniques. Over the years he has worked with most automotive manufacturers amongst which DaimlerChrysler, Ford, GM, Toyota, BMW, PSA, Honda, Hyundai, Porsche, VW-Audi and Fiat.

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