Tecosim research project: Reducing calculation times for crash models
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Due to increasingly shorter development times and high licence fees, there is a desire for calculations to be completed as quickly as possible while ensuring the same quality of results. As part of a research project TECOSIM realise significant saving on calculation times for crash models.
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- 1. Reducing calculation times for crash models Abstract of research project results
- 2. More details require more computing capacity 1. INITIAL SITUATION | Reducing calculation times for crash models2 | May 2016 § Today's vehicle models for crash simulation contain around three million elements and take between 24 and 48 hours to calculate, depending on the code and hardware § There is a desire for greater detail, so that special effects can be reproduced § This will increase the calculation time further § Due to increasingly shorter development times and high licence fees, there is a desire for calculations to be completed as quickly as possible while ensuring the same quality of results
- 3. Aims and specifications of the research project 2. TASK | Reducing calculation times for crash models3 | May 2016 § examine crash models in ABAQUS Explicit § Reduce calculation time by around 30 per cent § Significance/validity of models to remain same as in the base model § As less time and effort to adapt existing models as possible The project was funded by the German Federal Ministry of Economics as part of its Central Innovation Program (ZIM).
- 4. Method and procedure 3. SOLUTIONS | Reducing calculation times for crash models4 | May 2016 § Parts of the model which have no impact on results for a particular loadcase are defined as a rigid body. These are perfectly stiff and therefore require hardly any calculation time. § Rigid bodies automatically dissolved as soon as the component enters the influence zone of deformation § Multi-STEP and restart function are used in ABAQUS to dissolve the Rigid Body and re- start the model with current boundary conditions § The approach was checked on analogous models and applied to a complete vehicle afterwards
- 5. Preliminary studies on partial models 4. PROJECT DESCRIPTION / IMPLEMENTATION | Reducing calculation times for crash models5 | May 2016 § Testing the methodology: "switching from rigid to deformable" on a simple square tube § Challenge: element properties cannot be changed between two ABAQUS steps § Solution: import the current stress loads and node speeds and apply them to an updated model using a script § Apply the method to a partial model (vehicle front end 56 km/h against rigid wall) Method test: square tube against rigid wall Front end of a TEC|BENCH model
- 6. Verifying the method on a complete vehicle model 4. PROJECT DESCRIPTION / IMPLEMENTATION | Reducing calculation times for crash models6 | May 2016 § One rigid body per include (modelling time kept low) § Bumper include is the only one not set as rigid. If minimum stress loads occur there, all adjacent includes will be switched from rigid to deformable, etc. § Potential: more detailed sub-division into more rigid bodies since the body in white extends throughout the whole vehicle and thus rigids are also converted in the rear section at a very early stage.Partitioning into rigid bodies by includes – optimisation potential: subdivide body in white into several includes TEC|BENCH model: 520,000 nodes and 2.8 million degrees of freedom
- 7. Significant saving on calculation time § A saving of almost 20 per cent on calculation times for partial model and almost 10 per cent for complete vehicle model were achieved with almost identical results § A more detailed rigid body partition, separate from the includes, would lead to much more savings. § The method can also be adapted and optimised for different load conditions (front, side or rear) 5. RESULTS AND PROSPECTS | Reducing calculation times for crash models7 | May 2016
- 8. TECOSIM Technische Simulation GmbH Wolfgang Woost General Manager Wilhelm-Wagenfeld-Str. 3 D-80807 Munich Tel +49 (0)89 552 679-17 Fax +49 (0)89 552 679-22 Mail w.woost@de.tecosim.com www.tecosim.com Contact: | Reducing calculation times for crash models8 | May 2016