CAHRS Workshop

Testing for Crash & Safety Simulation

Hubert Lobo DatapointLabs
New York, USA

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DatapointLabs
Research quality material testing ISO 17025 production environment Results in 5 days (48 hour RUSH service) Web-based quotation & data delivery Domain expertise in CAE material calibration

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expert material testing

Your CAE data conversion

materials testing

TestPaks = Materials testing + CAE material parameter conversion

metal, plastic, foam, rubber, composites over 20 CAE software codes
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Topics
A test philosophy for representing rate dependency of materials Experimental technique including sampling and specimen geometries Assessment of crash material data quality, expected trends & validation Specific comments for unfilled and fiberfilled polymers, foams, rubber and metals.
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Getting pertinent properties

Importance of measuring the right property Artifact free data
Properly designed experiments eg. not using crosshead displacement to calculate strain

Traceable data (ISO 17025)

NIST traceable instruments Certified trained technicians
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Getting the right samples

Spatial variation
Properties vary with location Forming, stretching, molding

Environmental variation
Ageing and conditioning

Process variation
Degradation from processing Recycled materials
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Metals
Relatively well behaved Models designed to match behavior Challenges lie with post yield nonMises failure envelopes Scaling of yield surface with strain rate Work of Nakajima, Dubois, Hooputra

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Plastics
Not well behaved Models not designed for plastics crash simulation Complex models are expensive Can we develop best practices for adapting common models to plastics

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Plastics Behavior - Basics

Non-linear elasticity Elastic limit well below classical yield point Significant plastic strains prior to yield Post-yield with necking behavior
35 30 25 Engineering Stress (MPa) 20 15 10 5 0 0 .0 5 .0 1 0 .0 1 5 .0 2 0 .0 E n g in e e r in g S tr a in ( % )
d a ta P la s tic Po in t

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Plastics Rate Effects

Modulus may depend on rate

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Plastics Rate Effects

Fail strain may be rate dependent

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Material Testing
Instron servo-hydraulic UTM Dynamic load cell Test at 0.01, 0.1, 1. 10, 100/s strain rates Temperatures: -40 to 150C
tens_slow.mpg

Tens.mpg

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Test Specimens
ASTM D638Type V Preparation
CNC from plaque CNC from part Molded
E2

gate region

E1

Variability
processing orientation thickness

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Modeling simple ductile plastics

Modulus is not rate dependent Large strains to failure Post-yield necking Plasticity curves vary with strain rate Failure strain independent of strain rate LS-DYNA, ANSYS, ABAQUS, PAMCRASH
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Choosing EMOD
35 30 Engineering Stress (MPa) 25 20 15 10 5 0 0.0 5.0 10.0 Engineering Strain (%) 15.0 20.0
data Plastic Point

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Post-yield with necking (Deihl)

70 60 50 Stress MPa 40

yield point

neck propagation

necking starts
30 20 10 0 0 0.2 0.4 0.6 0.8 Strain mm/mm 1 1.2 1.4 1.6

UTM1-39.62-1 UTM1-39.62-2

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Fail Limitations
When FAIL f(strain rate)

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Modeling Rate Dependency

Cowper Symonds
Tensile Strength (MPa)
40 35 30 25 20 15 10 5 0 1.E-02 1.E-01 1.E+00 Strain Rate(/s) 1.E+01 1.E+02

Does not correlate well with plastics rate dependency

LCSR
Capture model independent behavior

data Cowper Symonds Eyring

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Eyring Model
Eyring Model
Yield stress v. log strain rate is linear Best form for plastics

Fit yield stress v. log strain rate data to Eyring equation Can submit to LSDYNA MAT24 as table using LCSR
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MAT24 validation
60 50
LS-DYNA Simulation

40
Stress (MPa)

Tensile Experiment MAT 24 Model

30

20

10

0 0 0.05 0.1 0.15

Strain (mm/mm)

0.2

0.25

0.3

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Brittle plastics
Modulus is rate dependent Small strains to failure Brittle failure Failure strain decreases with increasing strain rate LSDYNA MAT19

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Methodology for MAT 19

Determine elastic limit at quasi-static strain rate Use elastic limit for vonMises yield Define failure
failure stress v. strain rate table

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Ductile-brittle transitions
Non-linear behavior Failure depends on strain rate Models
LS-DYNA MAT89 PAMCRASH 103 Abaqus *ELASTIC *PLASTIC,Rate

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Fiber Filled Plastics

Digimat MX
Material model reverse engineered from standard experiment

Perform injection-molding simulation Apply Digimat material model to transfer data to crash simulation Crash model has spatially oriented properties
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Basic Digimat TestPak Protocol

Mold 100X300X3.16mm plaques
Edge gated on 100 mm end Long flow length Fully developed flow Highly fiber orientation

Cut test specimens by CNC 5 specimens each (0, 90 ) Obtain true stress-strain data
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Advanced Models
MATSAMP (LS-DYNA) Standard rate dependent model Add non-mises failure envelope
Compression Shear

Add triaxiality
Post yield transverse strain

Add unloading
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Pros and Cons

Better failure envelope modeling Greater cost More complex model Greater simulation accuracy in difficult cases Cost-benefit not certain for general use

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Foams
Different deformation modes
Crushable Elastic with or without damage Visco-elastic

Large volumetric strain component

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Effect of Poissons Ratio = 0

Material compacts by eliminating air No lateral deformation Poissons Ratio -> 0 Axial strain volumetric strain True for
open cell foams crushable foams

May not be true for

closed cell foams elastomeric foams
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Typical Stress-Strain Data

0.050 0.045 0.040 Engineering Stress (MPa) 0.035 Zone 1 0.030 0.025 0.020 0.015 0.010 0.005 0.000 0 20 40 60 80 100 Engineering Strain (%)

Zone 2

Zone 3

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Test Strategy
Compressive stress-strain
5 decades of strain rate
.01, .1, 1, 10, 100 /s

Temperatures
-100 to 150C
Hisp_comp.mpg

Optional tests
Tensile (for cut-off stress) Shear (as required)
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Test Instruments

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PU Foam-stress strain
0 .0 4 0 .0 3 5 0 .0 3 0 .0 2 5 Stress (MPa) 0 .0 2 0 .0 1 /s fi t 0 .1 /s fit 1 /s fi t 1 0 /s fi t 1 0 0 /s fi t

0 .0 1 5 0 .0 1 0 .0 0 5 0 0 0 .1 0 .2 0 .3 0 .4 0 .5 0 .6 0 .7 S tr a i n ( m m /m m ) 0 .8 0 .9 1

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PU Foam- rate effects

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PU Foam recovery
0.030 0.025 Engineering Stress (MPa)
Load

0.020 0.015 0.010 0.005 0.000 0 20 40 60

Unload

80

100

Engineering Strain (%)

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Conclusions
Choice of material model depends on
material test data situation complexity

Proper selection = reasonable model Simple improvements can add power Validated models represent baseline Models can be tuned for multi-axial loadings
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