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Crash Simulation Workshop 4 : Modelling Materials in Engineering

Automotive Crash Structures

Presentation · May 2006

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 4th CRASH TECHNOLOGY GUILD WORKSHOP
May 2006

Dr Paul Wood
Dr Claus Schley

© 2006 IARC
 Industry Partners

ARRK Technical Services

ARUP
Corus Automotive (TATA)
Dutton Simulation
GOM UK
HBM UK
Instron UK
Jaguar and Land Rover
MIRA Ltd
Novelis UK
Ricardo

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 2
 Materials Characterisation and
Simulation Project

© 2006 IARC
 Project Aim

Develop processes to generate and validate strain rate

dependent material data for use in crash simulation

Deliverable
• Code of Practice
• Material data generation
• Knowledge

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 4
 Processes to Generate and Validate Strain Rate
Dependent Material Data for Crash Design

Level 1 Level 2 Level 3

Generate material data

across strain rate range of
interest

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 5
 Background

Example of NCAP crash tests (low/high score)

• not mandatory but more challenging than legal

• safety sells vehicles

Simulated material inputs for virtual crash testing

• variability in strain rate dependent material data

• uncertainty in data transformation process
• high cost

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 6
 Example of NCAP Crash Test Results

a. Example of Low NCAP b. Example of High NCAP

Score (c.2003) Score (c.2003)

Adult occupant rating Adult occupant rating

Pedestrian rating Pedestrian rating
Test Scores: Test Scores:
Front 4 (25%) Front 15 (94%)
Side 14 (78%) Side 18 (100%)
Pedestrian 4 (11%) Pedestrian 10 (28%)

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 7
 Car Body Structure

Steel
sonst. steel
DC 03/04/06

Aluminium DX 54
DX56
ALMg3,5 Mn
180 MPa
ALMg3,5 Mn0,5
220 MPa
ALMg4,5 Mn0,4
260 MPa
ALMg4,5 Mn0,4 H24
300 MPa
ALMg0,5 4Si1,2 340 MPa
AC-300 HF 380 MPa
AlMgSi 400 MPa
AlMgSi 1 420 MPa
>320 MPa 500MPa (DOGAL 800)
D680 C
Guss
950 MPa (BTR 165)
© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 8
 Simulated Material Inputs for Virtual Crash
Testing

$
$ ====================
$ MAT (Material) cards
$ ====================
$
*MAT_PIECEWISE_LINEAR_PLASTICITY
$ Steel Type ? Grade ? Batch ? Date ?
$ MID Density E Poisson'sR YielStr
1 7.85E-9 210000.0 0.3 245
$SR Param C P LC (Load curve or table ID)
0.0 0.0 600 0 0.0
0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0
$
*DEFINE_CURVE
$
$ Usage:
$
600 0 1.0 1.0 0.0
0 245
0.00024890600 249.02161
0.0012489060 263.05911

0.10724890 565.39117
0.10824890 566.07971
0.35824889 802.9360

Family of strain rate Typical material card format

dependent flow curves in commercial simulation
software (ARUP LS-DYNA)
© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 9
 Low Variability in Tensile Material Data at
quasi-static speed

Engineering Stress-strain for Steel tested in 0 direction

Engineering Stress-Strain Data, Steel DP600
(EN 10002-1:
(standard specimen in 0 deg.50 mm gauge
direction, length)
50 mm gauge length)

600

500
Stress [MPa]

Specimen A1
400 Specimen A2
Specimen B1
300 Specimen B2
Specimen B3
Specimen B4
200 Specimen B5
Specimen C1
100 Specimen C2
Specimen C3
0
0 5 10 15 20 25 30
Strain [%]
© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 10
 Comparing Tensile Material Data Tested at Higher
Speed (Strain Rate of 10 s-1) across Ten Labs

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 11
 Project Implementation

1. Procure State of Art in Precision Servo-hydraulic

High Speed Test Equipment
• strain rate range 0.1 to 500 s-1
• main features of machine

2. Develop specimen designs and test procedures

• effective use of modelling
• strain gauges calibration
• compare new strain rate data

3. Validation techniques
• benchmark suppliers data
• develop component tests (bend-impact and low/high speed
crush)

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 12
 New High Speed Test Facility at IARC

Main Features:
Fast Jaw Grip
Actuator velocity: 1 mm/s up to
20 m/s under open loop control
(closed loop control up to 1
m/s) in tensile and
compression Knock-out Specimen

wedge
Fast Jaw (gripping of
specimen)

Velocity profile correction

Fixed or static grip head

Four column load frame

Improved system of
measurement at high
frequency (sensors in m/c and
on specimen, DAQ)

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 13
 Operation of Fast Jaw Clamp System

GRIP accelerated
to target velocity:
Then released to
grab specimen
in ~5 microsecs
after knockout
FAST JAW GRIP
Wedge in jaw hits
start position Plastic extension
spacer rod
of specimen
Positions of strain
gauge length
gauge sensors
follows
on specimen

Fixed end
© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 14
 IARC Specimen Designs for High Speed Testing

To a first approximation Strain Rate = Applied Velocity

Initial Gauge Length

Moving grip end at 15 m/s Fixed end

Moving grip end at 5 m/s

A target strain rate of 600/s requires a gauge length of 25 mm

A target strain rate of 80/s requires a gauge length of 60 mm
© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 15
 Raw High Speed Tensile Test Data
Load-Filtered Actuator Position, Steel DP600 (2mm), Dynamic (5 m/s)
Comparing Machine and Specimen 18
Mounted Force Sensor Outputs for 16
Test Speed of 5 m/s (~ 80/s) 14

12

Load [kN]
10

6
Machine Mounted Force Sensor Output
4
Specimen Mounted Force Sensor Output
2

0
0
LVDT Actuator Position [mm]

COMPARING RAW SENSOR OUTPUTS FOR TARGET VELOCITY 15.1 m/s

(~ STRAIN RATE = 605 s-1, DAQ Frequency set to 2.5 MHz)
Comparing Machine and Specimen 18 18

Mounted Force Sensor Outputs for Test 16 16

Speed of 15 m/s (~ 600/s) 14 14

LVDT Actuator Velocity

12 12

Force (kN)
10 10

8 8

6 6

4 4
MACHINE MOUNTED FORCE SENSOR OUTPUT
SPECIMEN MOUNTED FORCE SENSOR OUTPUT
2 2
LVDT VELOCITY m/s (OPEN LOOP CONTROL)
0 0
1 3 5 7 9 11 13

LVDT Actuator Position (mm)

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 16
 Effect of Specimen Inertia -----?????

Comparing Model Output with Model Input Data in a High Velocity Test
x
Conducted at 15 m/s
True Stress (scale not shown)

MODEL INPUT DATA (QUASI STATIC TRUE MATERIAL DATA)

MODEL OUTPUT FROM CENTRE NODE IN GAUGE LENGTH TO

MEASURE STRESS AND STRAIN

0
0% 2% 4% 6% 8% 10% 12% 14% 16% 18% 20%

True Strain (%)

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 17
 System of Measurement – Position of Strain Gauge
Sensors on Specimen

Strain gauge (FORCE)

sensor mounted on tab
of static grip length

Strain gauge (STRAIN)

sensor on gauge length

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 18
 System of Measurement – Velocity Profile Across
Specimen Gauge length

Velocity Profile Across Tensile Specimen with an Applied Grip Velocity of

15 m/s
18

16

14

12
Velocity (m/s)

10

0
0 5 10 15 20 25

Engineering Strain

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 19
 Instrumentation of High Speed Tensile Specimen

Moving grip end

Specimen Calibrated under
Quasi-static load
7

Voltage Output From Strain

y = 0.00053272x
6
R2 = 0.99946476
y = 0.00052737x
R2 = 0.99956864

Gauge Circuits
5

StrainGauge Signal, Gain 1000 [v]

4
60 mm GL
25 mm GL
Linear (60 mm GL)
3 Linear (25 mm GL)

Strain gauge on
gauge length 2

(quarter bridge) 1

0
0 2000 4000 6000 8000 10000 12000 14000
Force (static load cell) [N]

Static Force Applied to Specimen

Strain gauges on
static grip length
(full bridge)

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 20
 Instrumentation of High Speed Tensile Specimen
20.00 800

18.00
700
16.00

14.00
Moving grip end 600

Strain Rate [1/s]

12.00
Strain [%]

500
10.00
400
8.00

6.00 300
4.00
20.00 200 100
2.00
18.00 90
0.00 100
16.00 80
0.02225 0.0223 0.02235 0.0224 0.02245 0.0225 0.02255 0.0226 0.02265 0.0227
14.00
Time [s] 70

Strain Rate [1/s]

12.00 60
Strain [%]

10.00 50

8.00 40

6.00 30

4.00 20

2.00 10

0.00 0
0.037 0.0375 0.038 0.0385 0.039 0.0395 0.04 0.0405 0.041
© 2006 IARC
Time [s]
Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 21
 Validating Material Data

Aim

• Develop crash component tests to validate strain rate

dependent material data

Process

• Crush - Quasi-static and dynamic tests

Double hat versus single hat

• 3-point bend - Quasi-static and dynamic tests

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 22
 Crushing on Sled Rig

Double Hat

Top Hat

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 23
 Crush Deformation Modes

Double Hat

Top Hat

Sled impact tests results Zwick quasi-static tests results

© 2006 IARC

Sensitivity: Internal 4th Crash Technology Guild Meeting 18th May 2006 24
 Crush Strain Rate Sensitivity and Model Correlation

Average Force Computed Over Successive Displacement Intervals

. Test impact speed 6500 mm/s

1.2 . Test low speed 5 mm/s
. Model impact speed
1.1
Crush Force (normalised by peak

Model low speed

1
load in double hat )

0.9

0.8 Double hat

0.7

0.6

0.5 Top hat

0.4

0.3
7% 13% 20% 27% 33% 60%
Percentage Crush Displacement
(normalised by initial length of crush member )

© 2006 IARC

Sensitivity: Internal
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