Case study on types of materials and its effects on crash analysis

Objective :

To examine and observe the changes in element behaviours , while applying various types of material using material card in hyperworks during component undergoing deformation and comparing the results of each material

Procedure - CASE 1 :

1. Import/Upload the material model file given - FAILURE_JOHNSON_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 1 recommendation
   
   
   
   
4. Also create Failure card as failure johnson card for case 1 simulation and this failure card is created in the browser tab
   
   
   
   
5. After which Simulation RUN could be performed using Analysis panel in main menu
   
   
6. Choose RADIOSS option and select the required parameters , input file to save the generated files
   
   
   
   
7. Click RADIOSS to run the simulation and files will be generated in input file location
   
   
   
   
8. After simulation run , a dialog box shows the total number of cycles and simulation time
   
   
   
   
9. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
   
10. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
11. Using page window layout , split the window for convenienece
    
    
12. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
13. Click Apply
    
    
    
14. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
15. Similarly analyse using contour
16. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
17. Click Apply
    
    
    
18. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
19. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
    
20. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
21. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
22. Model saved as Law2_epsmax_failure
    
    
    

Procedure - CASE 2 :

1. Open the material model file given - FAILURE_JOHNSON_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 2 recommendation ( As per case 2 no changes compared to case 1 parameters )
   
   
   
   
4. Also create Failure card as failure johnson card for case 2 simulation and this failure card is created in the browser tab ( Only edit - Ifail_sh = 1 , Dadv = 1 , Ixfem =1 as compared to case 1 )
   
   
5. After which Simulation RUN could be performed using Analysis panel in main menu
   
   
6. Choose RADIOSS option and select the required parameters , input file to save the generated files
7. Click RADIOSS to run the simulation and files will be generated in input file location
   
   
8. After simulation run , a dialog box shows the total number of cycles and simulation time
   
   
   
   
9. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
   
   
10. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
11. Using page window layout , split the window for convenienece
    
    
12. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
13. Click Apply
    
    
14. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
15. Similarly analyse using contour
    
    
16. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
17. Click Apply
    
    
    
    
18. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
19. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
20. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
    
21. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
    
    
22. Model saved as Law2_epsmax_crack
    
    
    

Procedure - CASE 3 :

1. Open the material model file given - FAILURE_JOHNSON_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 3 recommendation ( As per case 3 no changes compared to case 1 parameters )
   
   
   
   
4. In this case 3 - detele the failure card and then run the simulation
   
   
5. After which Simulation RUN could be performed using Analysis panel in main menu
   
   
6. Choose RADIOSS option and select the required parameters , input file to save the generated files
   
   
7. Click RADIOSS to run the simulation and files will be generated in input file location
   
   
8. After simulation run , a dialog box shows the total number of cycles and simulation time
   
   
   
9. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
   
   
10. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
11. Using page window layout , split the window for convenienece
    
    
12. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
13. Click Apply
    
    
    
    
14. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
15. Similarly analyse using contour
    
    
16. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
17. Click Apply
    
    
    
    
18. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
19. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
20. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
    
21. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
    
    
22. Model saved as Law2_epsmax_nofail
    
    

Procedure - CASE 4 :

1. Open the material model file given - FAILURE_JOHNSON_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 4 recommendation ( As per case 4 changes - Eps_max value is deleted in material card )
   
   
   
   
4. There is no failure card in this case
   
   
5. After which Simulation RUN could be performed using Analysis panel in main menu
   
   
6. Choose RADIOSS option and select the required parameters , input file to save the generated files
   
   
7. Click RADIOSS to run the simulation and files will be generated in input file location
   
   
8. After simulation run , a dialog box shows the total number of cycles and simulation time
   
   
9. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
   
   
10. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
11. Using page window layout , split the window for convenienece
    
    
12. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
13. Click Apply
    
    
14. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
15. Similarly analyse using contour
    
    
16. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
17. Click Apply
    
    
    
    
18. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
19. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
    
20. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
    
21. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
    
    
22. Model saved as Law 2
    
    

Procedure - CASE 5 :

1. Open the material model file given - FAILURE_JOHNSON_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 5 recommendation ( As per case 5 changes - Material card is changed to Law 1 using Card image )
   
   
   
   
4. There is no failure card in this case
   
   
5. After which Simulation RUN could be performed using Analysis panel in main menu
   
   
6. Choose RADIOSS option and select the required parameters , input file to save the generated files
   
   
7. Click RADIOSS to run the simulation and files will be generated in input file location
   
   
8. After simulation run , a dialog box shows the total number of cycles and simulation time
   
   
9. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
   
   
10. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
11. Using page window layout , split the window for convenienece
    
    
12. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
13. Click Apply
    
    
    
    
14. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
15. Similarly analyse using contour
    
    
16. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
17. Click Apply
    
    
18. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
19. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
20. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
    
21. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
    
    
22. Model saved as Law 1
    

Procedure - CASE 6 :

1. Open the material model file given - FAILURE_JOHNSON_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 6 recommendation ( As per case 6 changes - Material card is changed to Law 36 using Card image )
   
   
4. Parameter values in material card for Law 36 is assigned as per recommendations given
   
   
5. Under N_funct which is assigned 1 , fct_ID created using curve
   
   
6. The curve is created in browser tab and a window appears where Click new
   
7. Enter X & Y values as per requirements and press enter with entering each value
   
   
8. Curve is created and close the window
   
   
   
   
9. Assign the curve in material card
   
   
   
   
10. Thus material card for case 6 created
    
    
    
    
11. There is no failure card in this case
    
    
12. After which Simulation RUN could be performed using Analysis panel in main menu
    
    
13. Choose RADIOSS option and select the required parameters , input file to save the generated files
    
    
14. Click RADIOSS to run the simulation and files will be generated in input file location
    
    
15. After simulation run , a dialog box shows the total number of cycles and simulation time
    
    
    
16. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
    
    
17. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
18. Using page window layout , split the window for convenienece
    
    
19. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
20. Click Apply
    
    
    
    
21. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
22. Similarly analyse using contour
    
    
23. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
24. Click Apply
    
    
    
25. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
26. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
    
27. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
28. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
    
    
29. Model saved as Law 36
    
    

Procedure - CASE 7 :

1. Import/Upload the material model file given - LAW27_0000.rad
   
   
2. Open properties in browser tab and asiign the best recommended properties for Ishell , Ismstr , Ish3n , N , Ithick , Iplas
   
   
   
   
3. Create a material card as per case 7 recommendation ( In this case - Law 27 selected in card image )
   
   Parameters in material card is assigned as per recommended
   
   
4. There is no failure card in this case
   
   
5. After which Simulation RUN could be performed using Analysis panel in main menu
   
   
6. Choose RADIOSS option and select the required parameters , input file to save the generated files
   
   
7. Click RADIOSS to run the simulation and files will be generated in input file location
   
   
8. After simulation run , a dialog box shows the total number of cycles and simulation time
   
   
   
9. After which open the 0001.out file that was generated during simulation run and check the energy error & mass error
   
   
10. Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
    At ideal conditions -15%
    
    
11. Using page window layout , split the window for convenienece
    
    
12. Select Hyperview option in toolbar and click load model to upload .h3d file from the generated files during simulation run
    
    
13. Click Apply
    
    
    
    
14. Observe the animation RUN and analyse the changes occuring in the elements and their reaction for a period of 5 seconds
    
    
15. Similarly analyse using contour
    
    
16. Select result type as Displacement or Vonmises , averaging method as simple
    Also use maximum and minimum measurement plotiing using measures icon in the toolbar
    
    
17. Click Apply
    
    
    
    
18. Next open Hypergraph , import T01 file using data file option to plot graphs
    
    
19. Plot ,
    Y Type - Global variables
    Y request - Hourglass energy , Total Translational energy , Internal energy , Kinetic energy
    Y component - MAG
    
    
    
    
20. Then select -
    Rigid wall/R-wall in Y type
    4 Rigid wall 1 in Y request
    Resultant NF , Resultant TF , total resultant force in Y component
    
    
    
    
21. Thus a model with particular material type assigned and simulation run has been carried out
    And tools like hypergraph , hyperview are used to analyse changes in behaviour
    
    
22. Model saved as Law 27
    

Comparison and Observations :

• There are few observations and comparisons between 7 cases carried out in the simulation run
  
  
• Comparing the Number of cycles and simulation time between the 7 cases
  
  
  
• By this Case 6 exhibits maximum number of cycles ( LAW 36 )
  
  
• Case 5 exhibits minimum number of cycles ( LAW 1 )
  
  
• Case 3 exhiits minimum simulation time ( LAW 2 wihout Failure card )
  
  
• Case 2 exhibits maximum simulation time ( LAW 2 with Failure card under Ifail_sh , Dadv , Ixfem assigned )
  
  

Observation on Energy error and Mass error :

• As far as the mass error is concerned , its NIL in almost all the cases
  
  
  
  

Energy error observation :

Energy error to very maximum level of +5% is acceptable model , -5% represents a good model and better to be close to 0%
At ideal conditions -15%

CASE 1 :

The energy error in case 1 starts at -0.3% --> 0.4% --> -0.4% --> 1.1% --> 0.2% for a period of 5 seconds

This shows in this case the energy error fluctuates up and down with lowest of -0.4% and highest of 1.1%

CASE 2 :

The energy error is case 2 starts at -0.3% --> 0.6% --> 0.2% --> 5.9% --> -1.0% --> 4.0% for a period of 5 seconds

This shows in this case the energy error fluctuates up and down with lowest of -0.3% and highest of 5.9% --> ( Highest error comparing all other cases )

CASE 3 :

The energy error in case 3 starts at -0.3% --> 0.6% --> 0.0% --> 1.2% --> 0.8 for a period of 5 seconds

This shows in this case the energy error fluctuates up and down with lowest of -0.3% and highest of 1.2%

CASE 4 :

The energy error in case 4 starts at -0.3% --> 0.6% --> 0.2% --> 3.0% for a period of 5 seconds

This shows in this case the energy error fluctuates up and down with lowest of -0.3% and highest of 3%

CASE 5 :

The energy error in case 5 starts at -0.3% --> 0.4% --> 0.2 --> 0.7% --> 0.6% --> 0.8% --> 0.5% --> 0.6% --> 0.2% --> 2.1% --> -0.3% --> 3.6% --> -0.3%

This shows in this case the energy error fluctuates up and down with lowest of -0.3% and highest of 3.6%

CASE 6 :

The energy error in case 6 starts at -0.3% --> 0.3% --> 0.1% --> 0.7% --> 0.6% --> 0.5% --> 0.3% --> 0.2% --> 0.6% --> -0.1% --> -0.3% --> -0.1% --> -0.2% --> 0.1% --> 0.7%

This shows in this case the energy error fluctuates up and down with lowest of -0.3% and highest of 0.7% --> ( Lowest error comparing all other cases )

CASE 7 :

The energy error in case 7 starts at -0.3% --> 0.6% --> 0.0% --> 1.1%

This shows in this case the energy error fluctuates up and down with lowest of -0.3% and highest of 1.1%

Animation observation : --> ( All the cases are compared at Frame 10 )

Case 1 : Elements are getting deleted and thrown away at frame 10

Case 2 : Few elements getiing deleted and few cracked at frame 10

Case 3 : All the elements are deleted and thrown at frame 10

Case 4 : Elements crack at minimum level at frame 10

Case 5 : Elements cracks are very minimal at frame 10

Case 6 : Elements are deleted in a linear way at frame 10

Case 7 : Elements are deleted as well as cracked in linear way at frame 10

Energy plot observation : ( Refer images above )

Hourglass energy : Almost zero (0) in all the cases

Total Translation Energy :
Increases linearly with time upto crtain limit and then turns to be constant in cases 1 , 2 , 3
Increases linearly like a slope with time increases in cases 4, 5, 6, 7

Kinetic energy :

Almost zero in all the cases but trembles at the position where the TTE becomes constant and internal energy trembles

Internal energy :

Follows the same path as TTE - Total Translational Energy but trembles at the position where kinetic energy trembles

Contour plots observation :

In contour plots , von mises stresses are plotted against all the cases in which all the cases start with minmum stress of value 0 and vary according to thier material nature

Case 1 : Maximum value goes upto 2.867E+02

Case 2 : Maximum value goes upto 2.855E+02

Case 3 : Maximum value goes upto 2.705E+02

Case 4 : Maximum value goes upto 4.244E+02

Case 5 : Maximum value goes upto 5.820E+03

Case 6 : Maximum value goes upto 1.011E+03

Case 7 : Maximum value goes upto 2.772E+02

• These values represent the maximum stress of the material at the similar strain rate but there is a difference in each material's stresses
  
  
• This is because of the nature of the material and its parameters assigned differs in all cases
  
  
• The one with very less stress denotes that the energy or stress on it has exceeded and the elements get deleted because of which the energy gets decipated
  
  
• On the other hand material that do not allow deletion of elements , withstands maximum stress possible and reaches maximum stress value

Result and conclusion :

Hence with the given input model file , various material cards were created and differences in thier simulation runs were examined & observed