Volvo Crash Developmentdyna Nordic 2014 VCC 141009 Reduced

CRASH CAE IN THE ALL NEW
VOLVO XC90 & SPA platform
New challenges
New CAE methods
Advanced materials with failure
Material failure with CrachFEM
Multi-cell Al extrusion crash boxes
Spot weld failure with HAZ method
Small overlap rating, IIHS
Pre-clamped screw joints/bushings
Virtual sensor setting
Ball joint pull-out/cam-out
Zero complete car prototypes
Rolling wheels
6-7 CAE loops per car derivative
Automated post processing
Predict all relevant legal and rating

load cases
Pre strained clips
Optimized crash pulse

2014-09-23
NORDIC LS-DYNA USERS FORUM 2014
VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL
Material & welding
2014-09-23
Material & welding
Body materials
XC90 Gen I
7% 1%
15%
43%
Mild Steel
High Strength Steel
Very High Strength Steel
Extra High Strength Steel
Ultra High Strength Steel
Aluminium
34%
XC90 Gen II
6%
27%
33%
9%
3%
21%
2014-09-23
Remark:
Boron steel:
Press hardened:
Material & welding
33%
38%
MF_GenYld+CrachFEM
Plasticity features of standard Crash CAE material models for metals:
von Mises yield locus.
Non-linear isotropic hardening.
Strain rate dependency.
Additional plasticity features of GenYld:
Plastic anisotropy (8 different yield loci).
Kinematic and mixed hardening.
Yield locus modifications (asymmetry, biaxial correction and shear waist).
Failure prediction criteria of CrachFEM:
Ductile normal fracture (growth and coalescence of micro-voids).
Ductile shear fracture (forming of shear bands).
Instability (localized necking)
2014-09-23
Material & welding
Spot weld HAZ modelling
Spotwelds in boron steel are

weaker then in other steel.
This is due to the Heat Affected

Zone (HAZ) around the weld.
Idea: semi-physical modelling:

Detailed, but not prohibitively detailed
Four solids in SW
One ring of elements (1.5 mm) in HAZ
CrachFEM in base material and HAZ
Modified properties in HAZ
Prediction of spotweld failure and macro cracks
2014-09-23
Material & welding
Spot weld HAZ modelling

HAZ-welds
100% in the deformed
Part Of the body
2014-09-23
Material & welding
Model content/complexity
2014-09-23
Complete CAE model with interior

Structure model:
CrachFEM materials
Detailed HAZ welds
Rolling wheels
New powertrain models
New chassis models
Steering mechanics from
wheel to steering wheel
Interior model:
Dummies
Seats & Belts
Detailed Instrument panel model
Carpets
Driver and Passenger airbag
IC (Inflatable Curtain)
Knee airbag
CrachFEM materials
2014-09-23
VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL,
Complete CAE model with interior

New VEA-engines
4-cyl diesel & petrol
Extruded Al
Lower load path
New front &rear chassis
2014-09-23
10
Interior and
Restraints
Designed
Around
You !
2014-09-23
11
Interior and
Restraints
New seats with
whiplash and off road
protection
2014-09-23
12
Interior and
Restraints
New Belts with
electric pretension to
keep you safe before
the crash occurs
Driver and passenger
airbags
2014-09-23
13
Interior and
Restraints
collapsible
steering column in X
2014-09-23
14
Interior and
Restraints
Interior Trim
2014-09-23
15
Interior and
Restraints
All together to keep
you safe
2014-09-23
16
more details in the Model

Important screw joints pre-clamped
during dynamic relaxation
(*INITIAL_AXIAL_FORCE_BEAM)
Screw joints with failure

Most rubber bushings meshed in
detail (rubber meshed with solid
elements)
Al-engine mounts meshed with solid
elements with failure
Anisotropic CrachFEM material for
all Al-extruded parts
2014-09-23
17
Influence of rolling wheels
Not rolling
2014-09-23
18
Influence of rolling wheels

Important for:
Barrier interaction
Tyre to ground
interaction
Total kinetic energy
2.8% higher
Remark:
*INITIAL_VELOCITY_GENERATION
Rolling
2014-09-23
More complex velocity initiation,

Improvement needed
19
Modeling of clips
Detection of clip detach
Metallic and plastic clips

are modeled in detail, with
initial stress state, in order
to capture clip detaching at
right load.
2014-09-23
20
Debugging & starting a 10 milj+ model!

Starting and debugging a 10 milj+ model is not an easy task
Maximum 5 working days are dedicated for this in our time plans
All subsystem models need debugging and test running prior to complete
model test and debugging
Debugging in pre/post processors and with scripts searching in d3hsp
Debugging by running standstill simulations and main load cases
Lots of manual debugging by experienced CAE engineers!
Several versions of the model to test (Diesel, Petrol, LHD/RHD, 2WD/4WD...)
Always remaining issues there is no perfect model!
2014-09-23
21
correlation
2014-09-23
Correlation
22
Improved pulse Correlation

CAE
Test
LHD EUNCAP pulse correlation, Vehicle Body pulse
Remark / Finding:
Global friction settings affects the result a lot!
2014-09-23
Correlation
23
Good pulse correlation - New CAE possibilities
2014-09-23
Correlation
24
Good pulse correlation - CAE acc data has ben used TO start
Trigg logic settings earlier in project
2014-09-23
Correlation
25
small overlap
2014-09-23
small overlap
26
IIHS small overlap - a CAE Challenge

40mph
25%
Failure need to be captured in:

All body materials
All exterior materials, joints, clips
All chassis parts
All weld connections
Most screw joints
Detailed wheel model that can puncture & crack
2014-09-23
small overlap
27
CAE
2014-09-23
TEST
small overlap
28
CAE
2014-09-23
TEST
small overlap
29
Ball joint pull-out / cam-out

Correlated chassi joint separations
needed in order to improve
correlation in small overlap
Ball Stud
Ring
Liner
Housing
2014-09-23
small overlap
30
Ball joint pull-out / cam-out correlation

Test procedure
Fpull-out
Fpush-out
Requirement
F > Freq
Requirement
M1 > Mreq
M1

2014-09-23
small overlap
31
Failure in the chassis, complete model

Important:
No unphysical
stack up/edgeing
All parts can fail
Rim can crack
Tyre can puncture
Tyre can separate
from rim
-
2014-09-23
small overlap
32
XC90 Car to car
2014-09-23
Total number of elements: 17 200 000

Simulation time: 250ms
Number of CPUs: 480
Run time: 84h
Number of elements reduced from 19 400 000 (two
complete cars) due to memory issues.
small overlap
33
Advanced post processing
2014-09-23
34

Post-processors with automatic generating functions
CAE/Test summary reports
2014-09-23
CAE/Test detailed reports

(embeded with animations, pictures, etc.)
CAE/Test deeper analysis
35
Cluster & load case adaption
2014-09-23
36
Crach CAE Servers

HP ProLiant Blade Systems:
cs3: 640 Xeon Hex Core @ 2.80/2.93 GHz
cs5: 640 Xeon Octa Core @ 2.66 GHz
cs7: 640 Xeon Octa Core @ 2.66 GHz
Crash CAE batch system: 14080 cores
Some extra blades

44 Tb hard disk with backup
240 Tb hard disk without backup
2 CPUs per blade

16 blades per cabinet
3 cabinets per rack
7 racks in each server

2014-09-23
37
Runtime efficiency
Full model
9.2M elements
Parts that has minor influence to the side impact

behavior, is replaced by rigid bodies with inertia
and mass and reduced subsystems
Full
Load case adapted

for side impact
Change
Shells
- Type 2
- Type 16
7742983
2805950
4937033
4882369
3047172
1835197
-37%
+9%
-63%
Solids
1426718
754763
-47%
Total
9169701
5637132
-39%
Runtime (144 cores)

2014-09-23
43.15h
22.07h
Load case adapted model

5.6M elements
-49%
Performance checked to give the

same response on interesting values
38
Large and Increasing number of loadcases

Pedestrian
Frontal impact
Low speed
Side
Impact
Head impact
Rollover / roof crush

Rear Impact
Large animals
2014-09-23
summary
39
2014-09-23
summary
40
Summary
Detailed modeling of connections is important (screw joints, welds, clips,

glue, bushings, ball joints)
Increased need for failure predictions to get better correlated models also in
solid parts
Running complete car crashes with full interior 10 milj+ models will be more
common in the future
Model complexity and CAE ambitions has increased as fast as

computational capacity at VCC
Advanced material models exist but what about friction? (considerable influence !)
This is only a glance of the CAE work performed in the SPA development the
last five years (42 CAE engineers, 10 nationalities , a great team!)
2014-09-23
summary
41
Thank you for your attention!

Volvo Cars Safety Center:
Oscar Centeno
Anders Sandahl
Anders Eriksson
Johan Jergeus
Emil Claesson
Weijia Wu
Per-Anders Eggertsen Mathias Retzlaff
Domenico Macri
Michelle Khoo

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CRASH CAE IN THE ALL NEW

VOLVO XC90 & SPA platform

New CAE methods

Advanced materials with failure

Material failure with CrachFEM

Multi-cell Al extrusion crash boxes

Spot weld failure with HAZ method

Small overlap rating, IIHS

Pre-clamped screw joints/bushings

Virtual sensor setting

Ball joint pull-out/cam-out

Zero complete car prototypes

6-7 CAE loops per car derivative

Automated post processing

Predict all relevant legal and rating

Pre strained clips

Optimized crash pulse

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Material & welding

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Material & welding

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Material & welding

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Material & welding

Spot weld HAZ modelling

Spotwelds in boron steel are

This is due to the Heat Affected

Idea: semi-physical modelling:

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Material & welding

Spot weld HAZ modelling

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Material & welding

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

Complete CAE model with interior

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL,

Complete CAE model with interior

New front &rear chassis

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL,

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL,

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL,

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

NORDIC LS-DYNA USERS FORUM 2014

VOLVO CARS, SAFETY CENTRE, ANDERS SANDAHL

more details in the Model

Screw joints with failure

NORDIC LS-DYNA USERS FORUM 2014