LS-DYNA

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 Agenda
Introduction to LS-DYNA
Static and dynamic analysis
Linear and Non-linear analysis
Sources/Types of non-linearities
Implicit and Explicit solvers
Central difference technique
Time integration (Time step)
Conservation of law of energy, mass and momentum
Material models used in DYNA
Elements used in DYNA
Hourglassing
Rigid body dynamics
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 Agenda (Contd..)
Interface/contacts
Loads and boundary conditions
Joints and connections
Seating system regulations
Workshop

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 Introduction to LS-DYNA

LS-DYNA is developed by Livermore Software

Technology Corporation (LSTC), Livermore, California.

L Livermore
S Software
DYNA DYNAmic analysis tool

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 Introduction to LS-DYNA (Contd..)
Need for software other than Ansys/Nastran etc
To solve impact related problem
1) To solve the crash related problem
2) To solve high impact problem
Problem related to the manufacturing process
1) Metal cutting process
2) Metal forming process
Problem related to large deformation
1) Failure analysis
2) Air bag deployment
3) Problem relented to explosion and shock wave

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 Introduction to LS-DYNA (Contd..)
Beyond Ansys and Nastran
Drop test
Impact (high Velocity and low Velocity)
Crash Analysis
Metal Forming Analysis
Explosion Analysis

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 Introduction to LS-DYNA (Contd..)

LS-DYNA is general-purpose, nonlinear Dynamic finite

element analysis
Analyze the non-linear Dynamic Response of Three-
dimensional inelastic structure.
Having Automated contact analysis Capability
LS-DYNA is one of the best viable methods of simulating
and analyzing the crashworthiness of automotive
structures.

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 Introduction to LS-DYNA (Contd..)
Limitation of traditional packages
What could not be
modeled?
Non-linear dynamic problem could not be modeled or difficult
using traditional package.
Problem of metal forming process are very difficult for
traditional FE solver.
Dynamic Large deformation or crash analysis.
Problem related to fluid structure interaction.
Problem related to high speed impact.
Air bag problem for crash analysis.

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 Equation of motion
Equation of motion for system of a single degree of
freedom
.. .
M x C x Kx F ext

K C

x
F

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 Static analysis
Total external forces are equal to total internal forces

Kd Fext F

d
No or very less inertial effects in static analysis
Loads and boundary conditions do not change w.r.t time
Static Point Forces Static Distributed Forces Body Forces
w(x) g
F

W=mg
Point Loads
Traction or Pressure Loads (Load per unit length or area) Inertial -
Body or Volume Loads (Load per Unit Volume) Gravitational

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 Dynamic analysis

Total external forces are equal to total internal forces

.. ..
M
M x C x Kx F ext
F
..
or M x F ext Fint with Fint Kx
d

Inertial effects are dominant in dynamic analysis

Loads and boundary conditions change w.r.t time.

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 Linear analysis
Linear analyses deal with problems in which the structural response is linear.
Therefore, if the applied forces are doubled, then the displacements and internal
stresses also double.
Problems that fall outside this domain are usually classified as non-linear.

Assumptions of Linear Static Analyses :

All deformations and strains are small.

Structural deformations are proportional to the loads applied. This infers that the loading
pattern does not change due to the deformed shape and no geometric stiffening occurs due to
the application of the load.
All materials behave in a linear elastic fashion. Therefore, the material deforms along the
straight line portion of the stress-strain curve (no plasticity or failures occur). Highly localised
stress concentrations are usually permitted as long as gross yielding does not take place.
Loads are all static. This means that the loads are applied to the structure in a slow or steady
fashion and in a way that makes them time independent (are assumed to be constant for an
infinite period of time). No boundary condition varies with time or application of load.

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 Non-linear analysis
All real life problems are non-linear.
Sources or types of non-linearities are :

1. Material Non-Linearity
A. The stress-strain relations are no more linear.
B. The material does not follow the hooks law.

2. Geometric Non-Linearity
A. There is a nonlinear strain- displacement relationship.
B. The change in geometry (as the structure deforms) is taken into account when
forming the strain- displacement relationship and hence the equilibrium equations.
C. Geometric nonlinearity maybe due to large strains (membrane analyses or metal
forming) or small strains but with large displacements and/or rotations (cables, leaf-
springs, arches, fishing rods, snap-through buckling).

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 Non-linear analysis
3. Displacement boundary condition nonlinearities
A. The displacement boundary conditions depend on the deformation of the structure.
(nonlinear displacement-deformation relationship).
B. Most application is in contact problems, the displacement is highly dependant on the
relationship between two contact surfaces (normal force and friction present).
C. It is important to note that the bodies in contact could be in a state of linear elastic
stress; the nonlinearities all come from the contact definition.
D. Nonlinear contact occurs in impact (crash), assembly of mechanical components or
sliding frictional interfaces.
Geometric Nonlinearity
Geometrically nonlinear problems involve large displacements; large means that the displacements invalidate the
small displacement assumptions inherent in the equations of linear analysis. For example, consider a classical thin plate
subject to a lateral load; if the deflection of the plates midplane is anything close to the thickness of the plate, then the
displacement is considered large and a linear analysis is not applicable.
Another aspect of geometric nonlinear analysis involves follower forces. Consider a slender cantilever beam subject to
an initially vertical end load. The load is sufficient to cause large displacements. In the deformed shape plot, the load is
no longer vertical; it has followed the structure to its deformed state. Capturing this behavior requires the iterative
update techniques of nonlinear analysis.
For details on the finite element formulations for geometric nonlinearities, see Geometric Nonlinearities

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 Implicit method/analysis
Implicit refers to numerical method used to represent and solve time derivatives in the
momentum and energy equation.
Implicit analysis use the Newton Raphson/ Iterative method to calculate the displacement
at each node.
Time, t + t

n1 n2 n3 Time, t

The displacement at node n2 at time t+ t is equal to known values of displacement of the

nodes at n1,n2 &n3 at time t and also unknown displacement of the nodes n 1 &n3 at time level
t+ t . This results in system of simultaneous algebraic equations that are solved using matrix
algebra. Matrix Inversion
Large numerical effort is required to form ,store and invert the system of equations.

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 Implicit method/analysis
In the implicit procedure a set of linear equations is solved by direct
solution method.
The computational cost of solving this set of equations is high when
compared to the relatively low cost of nodal calculations with the
explicit method.
Implicit method uses automatic time integration based on full Newton
iterative solution method.
Newtons method seeks to satisfy the dynamic equilibrium at the end
of the time increment at time t+ t and compute displacement at the
same time.
The time increment t is relatively large compared to that used in the
explicit method.

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 Explicit method/analysis
The explicit method use central difference operator.
Time, t + t

n1 n2 n3 Time, t
The displacement of node n2 at time level t+ t is equal to known values of
displacement at nodes at n1,n2 &n3 at time level t. A system of explicit algebraic
equations are written for all the nodes in the time level t+ t. Each equation is solved in
turn for the unknown node point displacements.
Explicit methods are computational fast but are conditionally stable. The time step t
(i.e. time increment between two steps) must be less than the critical value otherwise
computational errors will grow resulting in bad solution
The term Explicit refers to the fact that the state at the end of increment is based
solely on the displacements, velocities & accelerations at the beginning of the
increment.

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 Explicit method/analysis
For the method to produce accurate results the time increment must be quite
small so that the accelerations are nearly constant during an increment. Since
the time increment must be small, analysis typically requires many thousand of
increment. Each increment is inexpensive because there are no simultaneous
equation to solve. Most of the computational expenses lies in the element
calculations to determine internal forces of the elements acting on the nodes.
Contact conditions & other extremely discontinuity events are rapidly
formulated in the explicit method and can be enforced on node by node basis
without iteration. The nodal accelerations can be adjusted to balance the internal
and external forces during contact. The most striking feature of the explicit
method is the absence of global stiffness matrix which is required with implicit
methods. Since the state of model is advanced explicitly. Iterations & tolerances
are not required.

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 Implicit Vs Explicit analysis
Implicit calculations lead to an system of equations including the
complete model.
Explicit calculation leads to simple equations for each degree-of-freedom.

Example: Static analysis (Implicit)

Kd F d K 1F
| | 0 0
| | | 0
K
0 | | |

0 0 | |

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 Implicit Vs Explicit analysis
Implicit
The dependent variables are defined by coupled sets of equations, and
either a matrix or iterative technique is needed to obtain the solution
Unknown appears on both sides of the equation
x(t+h) = x(t) + h f(x(t+h))

Explicit
A direct computation of the dependent variables can be made in
terms of known quantities
Unknown appears only on one side of the equation
x (t+h) = x(t) + h f(x(t))

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 Implicit Vs Explicit analysis
Implicit
A global stiffness matrix is computed, inverted and applied to the nodal out of
balance force to obtain a displacement increment.

Explicit
Internal and external forces are summed at each node point and a nodal
acceleration is computed by dividing by nodal Mass.
[M]{x} = [Fext]n - [Fint]n
Solution is advanced by numerical integration of the above computed
acceleration in time.
Courant condition limits largest stable time step.
Typically requires many relatively inexpensive time steps.
Well suited for dynamic simulations such as impact and crash (short duration).

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 Implicit Vs Explicit analysis
Explicit Implicit

+ Ideal for Highly Non-Linear short + Unconditionally stable for any

duration transient events
+ Low Memory requirements
+ Mature Contact treatments
+ Inexpensive Timestep Calculations
- Limited by Courant stability limit
Need to ignore geometric details
- Long duration events not feasible
load/time step
+ Geometric details can be included.
A huge benefit for certain
automotive structures
+ Ideal for Long and Short Duration
events
- High Memory Requirements
- Very expensive Time Step
calculations
- Contact Inexperience

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 Choosing the type of solver

Explicit
Short duration
High Strain-rate
Inertia dominated

Implicit
Static
Quasi-static
Zero to low strain-rates

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 Time integration
Main objective is to find unknown displacements by
numerically integrating the equations of motion which is
a second-order linear/nonlinear ODE

For a single degree of freedom with no damping:

Linear Non-Linear

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 Time integration (Contd..)
Among many explicit methods, the central-difference
technique is the most popular and is used in LS-DYNA

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 Time integration (Contd..)

Discretization in Time

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 Time integration (Contd..)

Current Time

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 Time integration (Contd..)

Current Acceleration

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 Time integration (Contd..)

Mid-step parameters

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 Time integration (Contd..)

Mid-step velocities

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 Time integration (Contd..)

Unknown displacements

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 Time integration (Contd..)
Choosing an incremental timestep is based on the highest
natural frequency of the system

Courant Frederick Levy (CFL) Criteria

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 Time integration (Contd..)
Increasing CFL based timestep
Stems from the desire to improve job turnaround with
negligible effects on accuracy
Two method exists
Mass Scaling
Stiffness scaling
Mass Scaling
Sound speed is slower in denser materials thereby allows larger
time-step
Stiffness Scaling
Sound speed is slower in softer materials thereby allows larger
time-step

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FE models for dynamic analysis

CONTACT
INTERFACES
CONTACT ENTITIES
COMMON NODES
BOUNDARY COND. SPRINGS/ DAMPERS
STONE WALLS SPOT WELDS
JOINTS
JOINTS
SECTION MATERIAL
properties PART II

PART I
geometry Topology

GROUND
RIGID BODY MERGE
TIME STEP

SIMUALATION TIME

INITIAL VELOCITIES OUTPUT

MODEL SETUP

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 A FE Model
Material Model (stiffness, density)
Section Properties (thickness, integration points)

SECT 1 MAT 1 SECT 2

PROP. SET 1 PROP. SET 2

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Materials, Sections and Parts
MAT1
TYPE MAT2
DENSITY TYPE
STIFFNESS DENSITY
SECTION 1 STIFFNESS
TYPE
SECTION 2
INT. RULE
TYPE
THICKNESS
INT. RULE
(ELEM. FORM)
THICKNESS
PART 1 (ELEM. FORM)
MATERIAL
PART 2
EOS
MATERIAL
ELEMENT EOS
PART
NODE 1, ...

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 Materials, Sections and Parts
Materials
About 100 models
elastic
elastic-plastic
visco-elastic
rubber
foams( crushable, uncrushable)
Sections
solids
shells
bars
thick shells

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 Elements
Basic Element Types
Solids
Shells
Beams
Discrete
The choice of formulations depends on
accuracy requirements
speed requirements
type of material to model
type of simulation

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 Elements
The formulations differ wrt:
order of element (linear, quadratic)
number of integration points
theory used to create element
Reissner-Mindlin based (RM)
Continuum based
Element formulations, shells
Huges-Liu: continuum, 1pt
Belytschco-Tsay: RM, 1pt
BT-membrane: RM, 1pt
S/R Huges-Liu: continuum, 4pt
FI BT membrane: RM, 4pt

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 Hourglassing
Hourglassing is a non-physical, zero energy mode.
Undesirable phenomenon that occurs due to reduced integration;
Affects brick, quadrilateral shell and 2-D elements; Can be eliminated
through full integration.
Can be identified through the hourglass energy reported in the d3hsp
and other output files; Should normally be less than 5% of deformation
energy
1-point integration (reduced integration)

4-point integration (full integration)

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Hourglassing

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Hourglassing

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 Hourglassing
Can normally be minimized through good modeling practices.
General principles include use of a uniform mesh and avoiding
application of concentrated loads on a single point.
Mesh refinement, in general, often reduces hourglassing effects.

Hourglass modes can be controlled either

Through adding stiffness which resists hourglass modes but not
rigid body motions or linear deformation fields; this is
recommended for low velocity deformations and automotive crash
Through damping velocities using bulk viscosities in the direction
of hourglass modes; this is recommended for high velocity
deformations and is the preferred method for solid elements

Hourglass control implemented through the use of the keyword

*HOURGLASS

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 Element formulations, Solids

CONSTANT STRESS 1 pt
FULLY INTGRATED 8 pt
14 POINT QUADRATIC 14 pt

For crash simulations linear elements are

used
Fully integrated elements are often used for
soft materials with large loads, such as foam.

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 Element formulations, Solids
Bending Characteristics of solids
1-PT
8-PT

M M

8-PT
STIFFNESS = 0
2 ELEMENTS STIFFNESS 0
(ELASTICITY)

M M

STIFFNESS 0
(ELASTICITY+PLASTICITY)

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 Element formulations, Beams
HUGES-LIU CONTINUUM BASED
BELYTSCHKO-SCHWER COROTATIONAL
TRUSS NO BENDING, SHEAR

Through thickness integration

1-POINT

1 2

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 Element formulations, Beams

Through Thickness Integration

2-POINT

Lamina parallel to
reference surface

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 Rigid bodies
A rigid body cannot deform.

dz dy

RY
R
Z
dx
RX

d n f(d CG ) f(R CG )
Rigid body has 6 degrees of freedom, 3 transnational
and 3 rotational.

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 Rigid bodies (Contd..)
Rules For Rigid Bodies:
Two rigid bodies cannot share the same node

M1
M2
F
1
F
CG1
2
CG2
n

Constraints must be applied to part or all nodes.

Fa

M
n1 Fb
CG

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 Rigid bodies (Contd..)
Rigid bodies defined by Material Model MAT 20.
Degrees of freedom for rigid body restricted to translations and
rotations about center of mass.
Rigid bodies can be attached to flexible bodies through the
keyword *CONSTRAINED_EXTRA_NODES.
Rigid bodies can be attached to other rigid bodies through the use
of joints.
Important to assign realistic material properties to rigid bodies
since these are used to calculate sliding interface parameters.

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 Joints
Joints can be created only between two rigid bodies.

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 Interface/Contacts

Overview
Identified by locations to be checked for penetration
(nodes, node sets, parts, part sets, segment sets).
Search for penetrations every time step.
Penalty and Constraint based contacts.
Penalty based contact algorithms: restoring force
proportional to penetration depth.
Penalty based contact algorithms: apply to rigid and
flexible bodies.

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 Interface/Contacts

Slave Nodes

4-node quad 3-node tri

Brick segment

Master Segments

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 Interface/Contacts
For each slave node
Identify closest master segment; Various algorithms exist for this
purpose.
Check if slave node penetrates this segment based on projections.
Add a linear spring (tension only) to the model if penetration is
detected; this will lead to a spring force on the slave node, and a
distributed reaction force on the nodes on the master segment.

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 Interface/Contacts

Contact interfaces

PENALTY FORMULATION
d
F=k*d k=f(K,A,V,fsi)
K=Bulk modulus
A=Element area
master
V=Element volume
fsi=Penalty scale factor
slave

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 Interface/Contacts
Penalty stiffness:
Determines the size of the force applied on the nodes in
contact.
High penalty - smaller penetrations
- larger risk for instability
Penalty stiffness depends on:
- element volume
- contact segment area
- element stiffness

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 Interface/Contacts
Surface to Surface contact

Master - slave contacts:

t = t1+

t = t1
Fs1 Fm2

Fm3 f s k d ps Master Slave

Fs3 Fm3

fs = penalty scale factor

k = proportional constant Fm4
Fs4
dps= penetration at node 3 Fm5
Fs5

dp3

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 Interface/Contacts
Single Surface contact

Fs8 Fs2

Fs1
Fs9

Fs10

Considers when a part contacts itself

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 Units
ms, mm, kN, kg

Steel: 210kN/mm^2, 7.85e-6kg/mm^3

Aluminum: 70kN/mm^2, 2.5e-6kg/mm^3

s, mm, N, Ton

Steel: 2.1e5N/mm^2, 7.85e-9 Ton/mm^3

Aluminum: 0.7e5N/mm^2, 2.5e-9 Ton/mm^3

e-9 accounts for the m in N (1.e-6*1.e-3)

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 Output controls
OUTPUT DATA
- Output data for animations
- Output data for plotting
ANIMATIONS:
Position, displacement, velocities, acceleration,
stresses and strains are stored in binary files with
an interval specified by the user.
PLOT DATA:
Various variables can be stored and are normally
stored in different ASCII files depending on type
of data

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 Output controls
OTHER COMMON CONTROL OPTIONS:
- Time step computation method
- Standard formulations for beams and shells
- Global penalty for sliding interfaces
- Input method for materials and parts
- Global system damping
- Number of CPUs for execution
- Coupling options (MYDAMO)
- Mass scaling
- Dynamic relaxation
- ALE options

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 Post-processing
Output File - d3hsp File (ASCII)
Errors and warnings
Echo of input data
Critical contact time step - must not be smaller then the actual
time step (search for surface timestep)
Initial contact penetrations (search for penetration)
Masses, COGs, and Inertias (search for mass of body)
Mass scaling information (search for added mass). Should not
be larger than 5% of the total mass.
100 most critical time steps (search for 100 smallest
timesteps). If just a few elements spoil the time step, try to
repair the mesh or use mass scaling.

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 Post-processing
Animation Data - d3plot Files
Animation
Gives displacements, velocities, accelerations,
stresses, strains, )
Translate in HyperMesh .res file using hmdyna or use
HyperView
Check for plausibility (contacts, penetrations, overall
deformation)
Check for failing regions (plastic strain)
Shell results are given on the different planes of the
shells
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 Post-processing
Plotting Data - ASCII Files
xy plotting
glstat: Energies
watch kinetic energy if mass scaling is used
watch hourglass energy to be < 5% of internal energy
watch interface energy
check how kinetic and internal energy behave to each other
stability of solution (no jumps in energy, or noise)
nodout: Displacements (calculate intrusions, relative
displacements, distances)
rcforc, secforc, rwforc, : Forces, accelerations (very noisy,
need filtering to obtain essential information)

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VEHICLE CRASH
LEGISLATION

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 US REGULATION
FMVSS201 Occupant Protection in Interior Impact
FMVSS208 Occupant Crash Protection
FMVSS207, 208, 210 Restraints and Seats
FMVSS214 Side Impact Protection
FMVSS301 Fuel System Integrity (not just rear crash)

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Frontal Impact - 50 km/h - 0 degrees - barrier impact, without occupants
Test Purpose - steering intrusion and fuel system
Applicable Law - ECE-R12 (Europe)
ECE R34 (Europe)
TRIAS 33 (Japan)
GS 36 (Gulf States)

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Frontal Impact - 50 km/h - 0 degrees - barrier impact, without occupants
Test Purpose - occupant protection, front airbag, vehicle structure
Applicable Law - TRIAS 47 (v = 50 km/h +/- 2 km/h) (Japan)
ADR 69/00 (v = >48 km/h) (Australia)
Article2 (South Korea)

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Frontal Impact - 56 km/h - 0 degrees to 40% overlap into deformable barrier (driver
side)
Effective for new models - 01/10/1998
Effective for new registrations - 01/10/1998
Test Purpose - Injury criteria, vehicle structure, fuel system, steering intrusion
Applicable Law - ECE - R94 (Europe)
96/79/EG (European Community)
ADR (Australia)

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Side Impact - 56 km/h - 90 degrees with moving deformable barrier
Test Purpose - Side Airbag, injury criteria (occupant protection), vehicle structure,
fuel system

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Side Impact - 56 km/h - 90 degrees with moving deformable barrier
Applicable Law - ECE (R95) - Europe
96/27/EG - European Community
300mm barrier height, for vehicles with H-point
<700mm above ground
Effective for new models 01/10/1998
Effective for new registrations 01/10/2003
Planned Regulations ADR 72/00 in accordance with 96/27EG ECE - R95
or
FMVSS 214
Article 18 in accordance with 96/27EG (ECE-R95 with 300mm
barrier height) (proposed introduction 01/10/2003) (Japan)

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Rear Impact - 38 km/h - 180 degrees - 100% overlap with rigid moving
barrier 1100 kg
Test Purpose - Belt tensioner, injury criteria, vehicle structure, fuel system
Applicable Law - ECE - R32 (Europe)
TRIAS 33 (up to 1st April 1999) (Japan)

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Rear Impact - 50 km/h - 180 degrees - 100% overlap with rigid moving
barrier 1100 kg
Test Purpose - Injury levels, vehicle structure, fuel system
Applicable Law - TRIAS 33 (from 1st April 1999) (Japan)

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Rear Impact - 48 km/h - 180 degrees - 100% overlap with rigid moving
barrier 1800 kg, w/ 50%-Dummy
Test Purpose - Fuel system integrity
Applicable Law - FMVSS 301

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Thank You!

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