Performance Improvement of Recently Updated FE Dummy Models - Humanetics

Performance Improvement of

Recently Updated FE Dummy

Models

Nishant Balwan

Humanetics Innovative Solutions, Inc

Content

0. Introduction

1. H3-50 Express Dummy Model

2. H3-50 FE Dummy Model

3. ES2 Dummy Model

4. ES2-RE Dummy Model

5. Q1 Dummy Model

6. Q1.5 Dummy Model

7. Q6 Dummy Model

8. Discussion and Conclusion

0.0 Introduction

• Humanetics is closely working with customers and Radioss experts

(Altair) to improve the performance of FE dummy models.

• This presentation covers performance of Radioss code dummy models

after recent updates.

• Theses updates are feedback or issues from

• Customers

• Radioss experts

• Internal requests

Chapter 1 H3-50 Express Dummy Model

1.1 H350 Exp – Release Updates

• Current Release: v7.1.1

• Updates from v7.1:

1. Added ankle friction joint

• To apply friction moments

2. Adjusted mass of dummy to 78.68kg (including shoes)

• Illustration on next slide

3. Modified chest stiffness spring

• Stiffness curve were scaled down to achieve better correlation

4. Added neck stop angle

• Neck stop angle added to limit neck moment to ±5⁰

5. Modified inertia of the joints springs

• Inertia was increased to reduce noise level in responses

1.2 H350 Exp – Mass Distribution

Assembly Express Model (kg) FE Model (kg) Physical Model (kg)

Head Assembly 4.46 4.46 4.45 0.05

Neck Assemby 1.43 1.43 1.54 0.05

Upper Torso Assmebly 16.84 16.84 17.19 0.36

Lower Torso Assembly 19.88 19.88 23.04 0.36

Upper Leg Assembly, Left 7.39 7.39 5.99 0.09

Upper Leg Assembly, Right 7.38 7.38 5.99 0.09

Lower Leg Assembly, Left 5.51 5.51 5.44 0.14

Lower Leg Assembly, Right 5.51 5.51 5.44 0.14

Upper Arm Assembly, Left 2.19 2.19 2.00 0.05

Upper Arm Assembly, Right 2.19 2.19 2.00 0.05

Lower arm/Hand Asssembly Left

2.40 2.40 2.27 0.09

Lower arm/Hand Asssembly Right

2.41 2.41 2.27 0.09

Total Mass 77.58 77.58 77.70 1.18

1.3 H350 Exp – Thorax Certification Test

• Speed: 6.7m/s

• Mass: 23.36kg

Test 1 Test 2 v7.1 v7.1.1

Chapter 2 H3-50 FE Dummy Model

2.1 H350 FE – Release Updates

• Current Release: v7.1

• Updates from v7.0.1:

1. Added ankle friction joint

• To apply friction moments

2. Modified inertia of the joints springs

• Inertia was increased to reduce noise level in responses

3. Modified positioning angle (RY) to 22.5⁰

• Release position of dummy is modified. Global Y-axis angle is

adjusted to 22.5⁰

2.2 H350 FE – Thorax Test

• Speed: 3.0m/s

• Mass: 23.36kg

Test 1 Test 2 Test 3 v7.1 v7.1.1

2.3 H350 FE – PDB Sled Test

• PDB sled is rigid sled with belts and without airbags.

• It is used to rate the performance of frontal impact dummies.

Acceleration Pulse Setup

2.3 H350 FE – PDB Sled Test

Test 1 Test 2 Test 3 v7.0.1 v7.1

2.3 H350 FE – PDB Sled Test

Test 1 Test 2 Test 3 v7.0.1 v7.1

2.3 H350 FE – PDB Sled Test

Test 1 Test 2 Test 3 v7.0.1 v7.1

Chapter 3 ES2 Dummy Model

3.1 ES2 - Release Updates

• Current Release: v4.1.3

• Updates from v4.1.2:

1. Hip friction joints were added

• To apply friction moments

2. Ankle friction joints were added and updated X and Z DOF for positioning

• To apply friction moments

3. Lower neck friction joint was added and provided Y DOF for positioning

• To apply friction moments

4. Lumbar spine bent angle was updated to 3⁰

• For better positioning in vehicle against the seat back angle was

modified from 6⁰ to 3⁰

5. Arm to rib edge contact was added

6. Upper arm foam and rib foam stiffness are tuned

• Stiffness curves were scaled down to achieve better correlation.

3.2 ES2 - Certification Tests

Test 1 Test 2 v4.1.1 v4.1.3 • Speed: 4.3m/s

• Mass: 23.4kg

Pelvis Certification

Shoulder Certification

Sled mass: 317 kg

Velocity: 8.9 m/s

3.3 ES2 - WSU Sled Test

4

5

6

7

8

9

10

0 50 100 150 200

Ve

loci

ty, m

/s

Time, ms

Imposed Velocities - ES2 WSU test

6.8 m/s

8.9 m/s

Acceleration Pulse

Setup

• WSU Sled Setup:

• It is used to rate the performance of side impact dummies

3.3 ES2 - WSU Sled Test

Test 1 Test 2 Test 3 v4.1.1 v4.1.3

3.3 ES2 - WSU Sled Test

Test 1 Test 2 Test 3 v4.1.1 v4.1.3

Chapter 4 ES2-re Dummy Model

4.1 ES2-re – Release Updates

• Same updates has been applied to ES2-re dummy as that of ES2 and

similar response had been found out.

Chapter 5 Q1 Dummy Model

5.1 Q1 – Release Updates

• Current Release: v1.0

• Updates :

1. This RADIOSS release model is build from Humanetics

existing FE model beta released version 1.0

2. Some additional fine tuning was made in order to improve

the Radioss model response

5.1 Q1 – Head Certification Test

• Certification Test - Frontal

• Drop Height - 130mm

• Updates - Improved friction between head and rigid plate

Rigid Plate

Head

28°±2°

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

5.1 Q1 – Head Certification Test

• Certification Test - Lateral

• Drop Height - 130mm

• Updates - Improved friction between head and rigid plate

Head

Rigid plate

55°±2°

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

5.2 Q1 – Thorax Certification Test

• Certification Test – Frontal

• Speed – 4.3 m/s

• Updates – Modified the position of pendulum and tuned the rib skin material

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

Chapter 6 Q1.5 Dummy Model

6.1 Q1.5 – Release Updates

• Current Release: v1.0

• Updates :

1. The FE model was created based on physical Q1.5 dummy Rev B

JULY 2009.

2. Radioss FE model is created from the above mentioned model.

3. Material data for arms and leg are not provided, thus those include

in the model are fictive and need enhancement.

6.2 Q1.5 – Head Certification Test

• Certification Test – Frontal

• Drop Height - 130mm

• Updates – Tuned head skin material

Rigid Plate

28°±2°

Head

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

6.2 Q1.5 – Head Certification Test

• Certification Test - Lateral

• Drop Height - 130mm

• Updates –Tuned head skin material

55°±2°

Head

Rigid plate

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

6.3 Q1.5 – Neck Certification Test

• Certification Test – Frontal; Speed: 3.9m/s

• Updates - RADIOSS development made some correction in OGDEN material law in

v11. To tune the model for v11 OGDEN material property definition has been modified

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

6.3 Q1.5 – Neck Certification Test

• Certification Test – Lateral; Speed: 3.9m/s

• Updates - RADIOSS development made some correction in OGDEN material law in

v11. To tune the model for v11 OGDEN material property definition has been modified

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

6.4 Q1.5 – Thorax Certification Test

• Certification Test – Frontal

• Speed 4.3 m/s

• Updates – Modified the position of pendulum and tuned the rib skin material

Test 1 Test 2 Test 3 v1.0 v1.0 Updated

Chapter 7 Q6 Dummy Model

7.1 Q6 – Release Updates

• Current Release: v0.2

• Updates :

1. This RADIOSS release model is build from Humanetics existing

FE model beta released version 0.2

2. Some additional fine tuning was made in order to improve the

Radioss model response

7.2 Q6 – Thorax Certification Test

• Certification Test – Frontal

• Speed - 4.27m/s

• Updates – Modified contact stiffness between jacket and pendulum

Test 1 Test 2 v1.0 v1.0 Updated

Chapter 8 Discussion and Conclusion

Discussion and Conclusion

• H350, ES2, ES2-re and Q-series dummy models were updated.

• For H3-50 Express model:

• Mass distribution was adjusted to match FE model.

• Chest stiffness adjusted to achieve better correlation for certification test.

• H3-50 FE Model:

• Noise levels are reduced for H3-50 by modifying spring inertia which in turn helped to

improve correlation.

• ES2 and ES2-re Models:

• Lumbar spine angle was adjusted to position the model in seat according to test setup.

• Adding additional contact and modifying pelvis and rib material improved correlation of

certification tests

• Q-series Models:

• With tuned materials and properties, models showed better correlation for head drop and

thorax certification test.

• More enhancements would be made to improve the models as these models are first build

levels

• In most of the cases recently applied modifications tend to improve the

performance of the dummy models.

Acknowledgement

HUMANETICS THANKS ALTAIR AND FORD FOR THEIR

HELP AND COOPERATION THROUGHOUT THESE

PROJECTS