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Crashworthiness Workshop - Altair HTC 2012

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This was a 2012 Americas HTC Crashworthiness training presentation. This presentation focuses on the use of HyperWorks tools for Automotive Crash applications. It will also discuss the interface of …

This was a 2012 Americas HTC Crashworthiness training presentation. This presentation focuses on the use of HyperWorks tools for Automotive Crash applications. It will also discuss the interface of TeamCenter-HyperMesh integration for batchmeshing and setting up the model in HyperCrash for Analysis.

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  • 1. HTC 2012 : Crashworthiness Training Shan Bala Program ManagerInnovation Intelligence® May 15, 2012
  • 2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Agenda1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala2. Forming Results Initialization – Subir Roy3. Multidomain in Radioss – Jean-Pierre Bobineau
  • 3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.TeamCenter-HyperMesh Integration OverviewTeamcenter Side PLM XML EXPORT Import PLMXML Batchmesh Assemble SIEMENS Connections TEAMCENTER Export HM/decks Part#: Export PLMXML YT29-89112081-9901002 PLM XML EXPORT HyperWorks Side 3
  • 4. Solution Elements © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 5. Solution ElementsConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 6. Solution Elements - Details Configuration - The target is to use only one PLMXML Transfer Mode for all use cases. - The HYPERMESH Mapping Table is a configuration file available in the HYPERMESH directory. This file is common to all sites and can only be modified by the administrator.Process Environment- The user should be able to start manually - The Working Directory is the temporaryeach process independently either from location where Teamcenter andTeamcenter or from the working directory. HYPERMESH are exchanging the files.- The same process is applied for all use - The PLMXML File exported by Teamcentercases. is overwritten by HYPERMESH at the- The HYPERMESH-PLMXML Import and HYPERMESH-PLMXML Export process afterHYPERMESH-CAD Translation processes a copy of the original file has been created.may be considered as one unique process © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 7. Solution Elements Teamcenter – PLMXML ExportConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 8. Solution Elements Teamcenter – PLMXML ExportConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 9. Solution Elements HyperMesh – CAD TranslationConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 10. Solution Elements HyperMesh – PLMXML ExportConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 11. Solution Elements Script – Post OperationsConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 12. Solution Elements TeamCenter – PLMXML ImportConfiguration Teamcenter PLMXML HYPERMESH Data Model Transfer Mode Mapping TableProcess Script PLMXML PLMXML CAD PLMXML Post PLMXML HM HM HM TC TC Export Import Translation Export Operations ImportEnvironment PLMXML Working Teamcenter HYPERMESH File Directory © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 13. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.TeamCenter-HyperMesh Integration OverviewTeamcenter Side PLM XML EXPORT Import PLMXML Batchmesh Assemble SIEMENS Connections TEAMCENTER Export HM/decks Part#: Export PLMXML YT29-89112081-9901002 PLM XML EXPORT HyperWorks Side 13 © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 14. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.TeamCenter-HyperMesh Integration OverviewTeamcenter Side PLM XML EXPORT Import PLMXML Batchmesh Assemble SIEMENS Connections TEAMCENTER Export HM/decks Part#: Export PLMXML YT29-89112081-9901002 HyperWorks Side 14 © 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
  • 15. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Product Demo Demo
  • 16. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Agenda1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala2. Forming Results Initialization – Subir Roy3. Multidomain in Radioss – Jean-Pierre Bobineau
  • 17. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Agenda1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala2. Forming Results Initialization – Subir Roy3. Multidomain in Radioss – Jean-Pierre Bobineau
  • 18. Automated Forming Results Initialization for Full Vehicle Crash Models Subir RoyInnovation Intelligence® Director – Industry Solutions May 15, 2012
  • 19. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Outline Motivation Options Implementation Validation Application Conclusion
  • 20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Motivation1) Enable seamless incorporation of stamping effects into structural CAE to improve accuracy2) Leverage the effect of work hardening in stamping for possible weight reduction
  • 21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Option 1 • Map incremental analysis results • Use accurate incremental stamping analysis with adaptive mesh followed by mapping of results to structural mesh • Need stamping experts to define a feasible process which is difficult at the early product feasibility phase • Time consuming to run large number of parts • Possibility of error from mapping between somewhat different geometries
  • 22. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Option 2 • Use inverse analysis directly on structural mesh • Use One Step stamping analysis on the structural mesh and directly include the stamping results with the structural model • Addendum effect needs to be approximated with edge boundary condition • Possible to run large number of parts within a short time • Accurate enough for crash analysis
  • 23. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.One Step vs Incremental (Numisheet 2005 part) Incremental 1-step
  • 24. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Validation with Test Data (PSA, Altair EHTC 2010) Test With stamping Test
  • 25. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Validation with Test Data (PSA, Altair EHTC 2010)
  • 26. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.PSA Peugeot Citroën:HyperWorks Improves Development ProcessChallenge: Define a new simulation processdevelopment that includes accurate component data(thickness, residual strains, etc.)Solution:• Use HyperForm and RADIOSS in product development• Evaluate the impact of the manufacturing process onto the component formability• Seamlessly include forming results into RADIOSS crash simulationsBusiness Impact:• Reduce overall development time• Get a better correlation with test results• Improve product quality and process robustness Different deformation pattens (Reference, Without and With Blankholder) at 0,008 Sec“We are in the position to predict crash results via simulation much better than in the past. Buildingon this approach will lead to sustainable time savings and better products for our customers.” – Fabien Beda, Senior Engineer Crash & Fluid Simulations PSA Peugeot Citroën
  • 27. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Workflow
  • 28. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.User InterfaceI. GUI Mode • User remains in the model setup environment (HyperMesh/HyperCrash) • Stamping analysis conducted in background on user’s machine • Results posted for review • Include files created at the final step • Solvers supported: RADIOSS and LSDYNA • DemoII. Batch Mode • User provides the structural model and list of parts (from any pre-processor) • Stamping analysis launched in batch mode on a cluster • Include files created at the final step • Solvers supported: RADIOSS and LSDYNA • Demo
  • 29. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.User Interface (HyperMesh) Review results Select parts to initialize
  • 30. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.User Interface (HyperCrash) Select initialization option Review parts initialized
  • 31. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Features1) Material properties interpreted from crash model2) Addendum effect via edge Blankholder force via following options: a. Optimum FLC: Iteratively optimizes the blank holder force based on FLC to minimize failure b. Qualitative: Low, Medium, High, None c. Optional: Cut off plastic strain to eliminate local hot spots3) Automatic undercut check parts invalid for stamping4) Automatic hole filling5) Run in parallel mode
  • 32. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Materials SupportedRADIOSS • LSDYNA • M2_PLAS_JOHNS_ZERIL • MATL24 • M3_HYDPLA • MATL33 • M4_HYD_JCOOK • MATL36 • M22_DAMA • MATL37 • MLAW23 • MATL39 • M27_PLAS_BRIT • MATL81 • M32_HILL • MATL98 • M36_PLAS_TAB • MATL122 • M43_HILL_TAB • MATL123 • M44_COWPER • MATL133 • M48_ZHAO • M57_BARLAT3
  • 33. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Case Study 1: Ford Taurus Frontal Crash Model Plastic strains from forming
  • 34. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.LSDYNA Frontal Impact Crash Results Without stamping With stamping
  • 35. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Case Study 2: Dodge Neon Side Impact Model Plastic strains from forming
  • 36. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.RADIOSS Side Impact Crash Results Without stamping With stamping
  • 37. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Conclusion Incorporating stamping data can improve the correlation of structural CAE models for stiffness and deformation modes The magnitude of the influence of stamping on structural CAE depends on the loading path Standardization of structural CAE processes with stamping data for full vehicle models is now feasible Case studies to continue for NVH and Durability
  • 38. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Results Mapper 11.0• General purpose mapping tool inside HyperCrash • Map thickness, plastic strain, stresses, fiber orientation • Read forming data from Radioss, Dyna, AutoForm • Write mapped data to Radioss, Dyna, Abaqus input format • Map results between solids, hydro-formed parts • Handle symmetry • Fill holes • Batch process: Save and Replay • Demo Forming mesh Crash mesh
  • 39. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Thank you!HyperForm 1-step solver based stamping results initializationbeing used successfully at many OEMs and suppliers globally
  • 40. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Agenda1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala2. Forming Results Initialization – Subir Roy3. Multi-Domain in RADIOSS – Jean-Pierre Bobineau
  • 41. Multi-Domain Approach to Parallel Computations in Structure Dynamics using RADIOSSInnovation Intelligence® Jean-Pierre Bobineau May 15, 2012
  • 42. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computations Facts • Time step discrepancy is a major bottleneck in explicit computations • The smallest time step affects the performance of the whole model Method The target of the Multi-Domain approach is to reduce the needed CPU time in order to compute models with very different mesh sizes needing very different computation times. The goal is to reduce the elapsed time without losing accuracy. One of the challenges is to compute: cast, extruded and/or plastic parts (e.g. meshed with Tetra10 solid elements) inside a “classical” full vehicle crash model in order to predict the rupture mode of these specific detailed parts and their effects at global model scale. The idea is to replace this global model by physically equivalent sub-domains, separating parts with different minimal time step. Each sub domain is resolved as a distinct RADIOSS model using its own time step, the force and momentum transfers between them being calculated by a separate program handling stability constraints
  • 43. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computations Time step = dt_a Time step = dt_b Time step = dt_c
  • 44. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Multi-Domain approach to parallel computations Synchronization time
  • 45. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computationsRadioss V10 – multiple starter input file (Classical approach)• Each domain is built as a separate complete RADIOSS model using its owncomplete input files.• The RADIOSS runs are completely independent and do not communicatedirectly with each other. Each one is using its own time step.• The time step of each domain is arbitrary but to allow the best optimizationgain it should be significantly different from each other.• All communication, data transfers, time step synchronization, equilibrium andstability conditions on the domain frontiers are managed by the master program.The main interest of this strategy is that each model is independent and may be replacedby another one. This allows a modular approach for modeling, for example testing runswith equivalent domains with different mesh size (multigrid approach). Reason why thisapproach is still useful and is kept in Radioss V11.
  • 46. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computationsMulti-Domain inVersion 10 P1_0000.rad P2_0000.rad P3_0000.rad Radioss Radioss Radioss starter 1 starter 2 starter 3 P1_0000.rst P2_0000.rst P3_0000.rst input.dat Rad2rad Radioss Radioss Radioss engine 1 engine 2 engine 3 dt_a dt_b dt_c
  • 47. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computationsRadioss V11 – single starter input file format ( sub-domain approach)• One drawback of the classical approach is that it implies additional work forthe user to manually build several independent input files.• Furthermore it can become very long, difficult and a source of errors when thesmall domains are extracted from large and complex models like full vehicle.• The idea of the new approach in Radioss version 11 is to simplify the task ofthe user by building sub-domains automatically : • Only one starter input is now required including the entire model, like a classical Radioss computation. • The user only has to specify the parts of the model that he wants to place in sub-domains. • The starter automatically extracts the specified domains from the full model and generates one restart file for each domain.
  • 48. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computationsMulti-Domain inVersion 11 dt_a dt_b dt_c
  • 49. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computationsNew subdomain approach : definition of the subdomainsThe subdomains are specified by parts/SUBDOMAIN/subdomain_Idsubdomain_titleID_part1 ID_part2 ... ID_partnWhere:- ID_part are the Id of the parts that are in the sub-domain- subdomain_Id is the domain identifier.- subdomain_title is the sub-domain nameRadioss Engine input fileIn Radioss V11 as in V10 an engine input file is required for each domain and inorder to activate the multi-domain coupling these files must contain the followingcommand line:/RAD2RAD/ON
  • 50. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computations can be used to connect: – Shell nodes to Shell nodes – Shell nodes to Solid nodes – Solid nodes to Solid nodes – Beam nodes to Beam nodes
  • 51. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.PSA head impact v. windshield wiper motor Courtesy of PSA  Model Head impact : PART1 : 13803 shell elements PART2 : 303648 shell elements time step : 2.97e-7 sec [4.3%] [95.7%] time step : 8.00e-7 sec
  • 52. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. PSA head impact v. windshield wiper motor  Results quality Head acceleration vs time ---- MONO-DOMAIN ---- MULTI-DOMAINNote: In this case results quality is high also because there is small interaction between the 2 domains
  • 53. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. PSA head impact v. windshield wiper motor  Head impact : scalability performances (elapsed time) : 1 CPU 16 CPUs (2 nodes) 32 CPUs (4 nodes) 64 CPusMonodomain 63500 s 5420 s 3470 s 2790 sMultidomain case 1 27260 s 2740 s 2100 sMultidomain case 2 - // - 2584 s 1670 s 1390 sSpeed up case 1 2.33 2.00 1.65Speed up case 2 2.30 2.09 2.08 2.01 Time step factor = (dt domain 1) / (dt domain2) = 2.6 Mono-domain = complete model with common time step Speed UP = elapsed time Mono-domain / elapsed time Multi-domains Case 1 : using synchronisation with total CPU number allocated to all processes Case 2 : Case 1 + optimisation of MPI internal process communications (SPMD)
  • 54. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. NEON Full Frontal with refined subframet = 00.00 ms t = 80.00 ms Coarse Mesh in 1.Domain: Timestep = 5.0e-007 [s] Refined Mesh in 2,Domain: Timestep = 1.0e-007 [s]
  • 55. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. NEON Full Frontal with refined subframe Application : Neon model • Result o The results are the same between the mono domain computed with a time step of 0.1ms and the computation with sub-domain. Mono domain : 71700 s Multi domains : 35100 s Rigid wall forceSpeedup of ~2compared to theMono-Domain withsame (small) Time step Internal energy
  • 56. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Multi-Domain approach to parallel computations Conclusions
  • 57. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Open for questions…• Jean-Pierre Bobineau• Phone: (248) 709 09 42• E-Mail: jpb@altair.com

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