Side Pole Crash Simulation on Car BIW

Side Pole Crash Simulation 

Aim :

• To run a simulation for the Neon Side Pole Crash and to obtain the results in the post processing.

Objective :

 

• To check the unit system in the solver.
• To create an appropriate interface with friction 0.2 and recommended parameters.
• To check for the penetrations and intersections in the component.
• To create cylindrical rigid wall with a friction 0.1.
• To add extra mass to attain a target mass of 700 kg.
• To apply initial velocity to the car.
• Keep the min time step of 0.1micro sec & max of 0.5micro sec.
• Run the model up to 80 milliseconds.
• To find the sectional force in the Cross member.
• To calculate the intrusions at the B-pillar, Hinge pillar and at Fuel tank region.
• To calculate the peak velocity of an inner node of the door.
• To request TH for all the inputs created.
• To run the simulation.
• To plot the graphs in the post processing.

Theoretical FrameWork :

• A side collision is a vehicle crash where the side of one or more vehicles is impacted. These crashes typically occur at intersections and in parking lots, and when two vehicles pass on a multi-lane roadway.
• In the side pole impact collision cases, When the car gets crashes to the pole the load goes transferred to the car. So because of the load, it starts to deform and its contact with the dummy pelvis location. Pelvis position and orientation are important aspects of a vehicle occupant’s posture. Measurements of drivers’ or passengers’ pelvis locations are used for ergonomic or crash safety studies such as the development of posture prediction models, analysis of lap belt fit, and development of computational human models. 
• Due to this structure to pelvis contact, the load has transferred to the occupant. As only a very small crumble zone is available during a side pole impact, so we have to ensure that the impact forces are distributed over a wide area. The B-Pillars and side members along the flanks of the vehicle are mainly responsible for this. 
• The impact forces are transferred from B Pillar to the opposite side of the vehicle first and foremost via the transversely rigid seat and the center console. A further load dissipation path runs from the base of the B pillar to cross member under the seat and transmission tunnel braces.
• As per baseline study, identified the important load transfer path members are B-Pillar and its reinforcements, Roof bows, Sill, Transfers cross members. These parts stiffness increased by the way of design changes and material grade up. 
• In this test, we are going to give the velocity to be 24 km/h and we are going to take the diameter of the pole to be 254 mm as the standard diameter value according to the FMVSS 214 standards. 

Figure 1-Side Pole Crash With FMVSS 214 Standards.

 

Figure 2-Side Pole Crash.

[Note : According to FMVSS [Federal Motor Vehicle Saftey Standards].Assign a initial velocity of 20mph,1mph=0.44704 m/s,=20x0.4470,=8.94 m/s.]

 

Figure 2:1-Side Pole Crash.

 

Procedure :

 

Phase 1-Check unit system and either follow [Mg mm s] or [Kg mm ms].

• While opening hypermesh software,A user profile window will pop up,Switch to the radioss user profile as shown in below Figure 3 and start importing the model into the solver deck.

 

Figure 3-User Profile Window.

 

• Now after switch the user profile to radioss,import the model (starter file) into the radioss solver deck.
• To import the model,Go to Standard Panel >> Import >> Import Solver Deck.

 

Figure 4-Importing Model into Radioss Block.

• Import Solver Deck option should be selected to import the radioss starter file.

 

Figure 5-Selecting the Starter File to Import.

 

• Here the import browser will appear as shown in above Figure 5,Select the appropriate starter file to import into GUI.
• Switch the File Type to Radioss Block and import the model into GUI.Which is shown in below Figure 6.

 

Figure 6-Model Imported into GUI.

• Here the model is in wireframe mode,Switch to the shaded mode as shown in below Figure 7.
• To switch to shaded mode,Go to Visualization Tab >> Shaded Elements and Mesh Lines.

 

Figure 7-Visualization Tab to Switch to the Shaded Elements and Mesh Lines.

 

 

Figure 8-Shaded Elements and Mesh Lines Mode.

• Now go and check for the unit system of the model,To check for the unit system,Go to the Model Browser >> Control Cards >> BEGIN_CARD.
• Check for the unit system is shown in below Figure 9.

 

Figure 9-Unit System [kg,mm,ms.]

 

• Now go to the HyperCrash,To go,Go to Menu Bar >> Applications >> HyperCrash.Which is shown in below Figure 10.

Figure 10-HyperCrash Application.

 

• Make sure whether the unit system in hypercrash is [ kN, kg, mm, ms].Which is shown in below Figure 11.

 

Figure 11-HyperCrash Application Window.

• Now import the model in hypercrash,To import the model,Go to Menu Bar >> File >> Import >> Radioss.Which is shown in below Figure 12.

 

Figure 12-Import the Model into HyperCrash.

• Here select the appropriate Radioss File and import the model into hypercrash.Which is shown in below Figure 13.

 

Figure 13-Select the Appropriate Radioss File.

 

 

Figure 14-Model Imported into HyperCrash GUI.

 

Phase 2-Mass Balancing [ Adding Mass to the Model to get COG at Proper Position] :

 

• Here the COG is not in a proper position which is shown in below Figure 18.So we need add mass to get COG at proper position,Its like balancing.
• To Check the Mass and COG [Centre of Gravity],Go to HyperCrash Menu Bar >> Mass >> Balancing,Which is shown in below Figure 15.

 

Figure 15-Mass Panel.

 

Figure 16-Mass Balancing Panel.

 

• After hitting on the specs icon which is shown in above Figure 16.The initial position of COG will appear which is shown in below Figure 18.

Figure 18-Initial Position of COG.

 

• Now mass should be added to get COG in a proper position.It should be in centre of the cross member.
• To bring COG to the centre of the cross member,We should add a mass.
• To add mass,Go to Load Case >> Added Mass.Which is shown in below Figure 19.

 

Figure 19-LoadCase Panel.

 

• Now right click on the added mass browser and select Type=0,Where the mass will be added to every single node,Which is shown in below Figure 20.

 

Figure 20-Added Mass Browser.

 

Figure 21-Pick the Nodes to Add Mass by Right Clicking.

• Here right click on the [grnod_ID] Support* to pick the nodes to add mass,which is shown in a above Figure 21.

 

Figure 22-Pick the Nodes on the Model to Add Mass.

 

 

Figure 23-Nodes Picked on the Model to Add Mass.

• Here in the above Figure 23,The nodes were picked on the model to add mass.

Figure 24-After Adding Mass COG Position is Changed.

• Here after adding mass on the nodes,The COG position is changed which is shown in above Figure 24.

 

Figure 25-Pick the Nodes on Other Side to Add Mass.

• Here,Similarly pick the nodes on the other side of the cross memeber and add mass to bring the COG at centre of the cross member.

 

Figure 26-Got COG at the Centre of the Cross Member.

• The nodes have been picked and mass added to the other side of the model,which is shown in below Figure 27.

 

Figure 27-Nodes Picked and Mas Added on the Other Side.

 

Figure 28-Mass Added to the Nodes Which Picked.

• We have attained the mass by adding the mass to the nodes,Which is shown in below Figure 29.

 

Figure 29-Attained 700 kg Mass.

 

• Now export this file and save it in a specified location and import this model into hypermesh and check the total mass.

Figure 30-Export the Model from HyperCrash.

• Now import the exported model from HyperCrash to the HyperMesh.

 

Figure 31-Import Browser.

 

 

Figure 32-Model Imported into HyperMesh.

• Next go and check in hypermesh,Whether the we have attained 700 kg mass.
• To check,Go to Menu Bar >> Tools >> Mass Details >> Mass,COG,Inertia.Which is shown in below Figure 33.

 

Figure 33-Tools Menu.

 

 

Figure 34-700 kg Mass Attained.

 

 Phase 3-Check for the Penetration :

• Here check for the penetrations,To check,Go to Menu Bar >> Tools >> Penetration Check.Which is shown in below Figure 35.

 

Figure 35-Tools Menu.

 

• Next select the groups [Interfaces] to define.Which is shown in below Figure 36.
• Then click on the check to check penetrations in the model,If the penetration exsist,It throw a error in the status bar,If the penetration dosen't exsist,it will display No Collisions Found which is shown in below Figure 36.

 

 

Figure 36-Status Bar.

 

Phase 4-Create the Interfaces :

• Here for this model,TYPE 7 Contact Interface is created with the recommended parameters.Which is shown in below Figure 37.

Figure 37-Type 7 Contact Interface.

• Select the slave and master nodes by switching to the coponents and select all the components for slave and master nodes which is shown in below Figure 38. 

 

Figure 38-Slave and Master Nodes Selected.

 

Phase 5-Creation of Section at Cross Member :

• Here we have to create a section,the section should be created at the cross member.

• Next for creating section,We need frame,So we need to create frame first.To create frame Right click on the Solver Browser >> Create >> Frame >> Mov. which is shown in below Figure 39.

 

Figure 39-Creation of Frame.

• Next select the nodes to specify the location of the frame to be created on the model.
• Switch to the create by node reference,Now select the Node at Origin  >> Node at Z-axis >> Node at YZ Plane,Which is shown in below Figure 40.

 

Figure 40-Creation of Frame Tool Panel.

• The Nodes selected to create a frame at a specified location is shown in below Figure 41.

•  

Figure 41-Nodes Selected to Create Frame.

• The frame created is shown in below Figure 42.

 

Figure 42-Frame Created.

 

• Then create a section,To create a section,Right Click on the Solver Browser >> SECT >> SECT.Which is shown in below Figure 43.

Figure 43-Creation of Section.

• After selecting the SECT to create section,A parameter window will be opened left side.
• There will be Nodes (N1,N2,N3),Select the nodes to create a section.Which is shown in below Figure 44.

 

Figure 44-Selecting the Nodes.

• Next select the Frame ID,Which is shown in below Figure 45.

Figure 45-Selecting the Frame ID.

 

• Next Right Click on the grshell_id to select the elements,where we created the section.Which is shown in below Figure 47.
• Enter the values for deltaT and alpha.
• Coefficient of filtering (alpha=0.67).
• Time step for saving the data (deltaT=0.001).

 

Figure 46-Parameters Window.

 

Figure 47-Elements Selected.

• Every Parameters have been specified which is shown in below Figure 48.

 

Figure 48-Parameters Specified.

• A section has been created which is shown in below Figure 49.

 

Figure 49-Section Created.

 

• Now we have to check whether the section created for the rail component is fine or not fine.
• If all the nodes get realized in the elements,then the section created for rail component is fine.Which is shown in below Figure 50.
• A one row of elements should be maintained.
• To check Right click on the Section in the Model Browser >> Review.

 

Figure 50-Review of Section in the Cross Member Component.

 

• Similarly,We have to create a other two sections in the other cross members which is shown in below Figure 53.

Figure 51- Sections Created for the Three Cross Members.

 

 

Figure 52-Sections at Three Cross Members Created.

 

Phase 6-Creation of Intrusion at B-Pillar,Hinge Pillar and Fuel Tank Region :

• Here we have to create intrusions at B-Pillar,Hinge Pillar and Fuel Tank Region.
• First we have to create spring 1D element,To create,First create a temp node on the B-Pillar base component.Which is shown in below Figure 55.

Figure 53-Geometry Panel.

Figure 54-Temp Nodes Sub-Panel.

 

Figure 55-Temp Node Created.

• Next step is translate this node to other left B-Pillar,Cause to create spring,We need two nodes,So translate the node and create a temp node parallel to the,where the node created on the right side of B-pillar,Create a temp node with the reference of translated node.Which is shown in below Figure 56.

 

Figure 56-Temp Node Created on the Left Side of B-Pillar with the help of Node Translated from Right Side of B-Pillar.

 

Figure 57-Two Nodes Created to Create 1D Spring Element for Intrusion.

 

• Now create a spring,To create a spring element,Go to 1D >> Spring >> Select Node 1 and Node 2.Which is shown in below Figure 59.

Figure 58-1D Panel.

 

Figure 59-1D Sub-Panel.

 

Figure 60-Created 1D Spring Element at B-Pillar Region.

 

Figure 61-Created 1D Spring Elements at B-Pillar Region,Hinge Pillar region,Fuel Tank Region.

• The next one is to assign the mass and stiffness values for the created springs, in the parmeter region, as shown in below Figure 62.

Figure 62-Give Mass and Stiffness Values.

• Next create new collector and rename it as spring which is shown in below Figure 63.

 

Figure 63-Assign the 1D Spring Elements in the Collector Named Spring.

• Create a property and assign the property to the Spring Collector which is shown in below Figure 64.

Figure 64-Property Assignd to the Spring Collector.

 

Phase 7-Create Initial Velocity :

• Now we have  to give the initial velocity to the car.
• So to give the initial velocity we have to create INIVEL.
• To Create,Go to Solver Browser >> Right Click >> Create >> Boundary Conditions >> INIVEL.Which is shown in below Figure 65.

 

Figure 65-Creation of INIVEL.

 

• So,We want the car body to move in the x-direction so we have to give the velocity in the x-direction only.
• We need to give the velocity as 20 mph which we have to convert into the m/s. So after converting the velocity we got the velocity as 8.94 m/s. 

 

Figure 66-INIVEL Parameters Panel.

• Right Click on the gmd_ID and select all the components,Cause whole car body want to move in x Direction.Which is shown in below Figure 67.

 

Figure 67-Selecting all the Components to Give Initial Velocity.

 

Figure 68-Initial Velocity is Given.

 

Phase 8-Create Peak Velocity of Inner Node of the Door :

• Here we have to create a peak velocity,To create a peak velocity,First we have to create a node.
• We have to give peak velocity at the given node [337773].
• To find the node,Go to Display Panel.To find we have to display the numbers in the display panel.Which is shown in below Figure 69.

Figure 69-Display Panel.

 

• Select the node by id and eneter the id number and click on which is shown in below Figure 70,The node number will be displayed,We have to create a node there and to request TH for that node.

Figure 70-Display Numbers Panel.

• The node number is displayed,Which is shown in below Figure 71.

 

Figure 71-Node Number Displayed.

 

• Next,Create a TH for that node. Because,to know the peak velocity at that point.
• So,We have to request TH for that Node.
• To create a TH for that node, Right Click on the Solver Browser >> Create >> TH >>NODE.Which is Shown in below Figure 72.

 

Figure 72-Requesting TH for the Peak Velocity Node.

• The TH is requested for that node,Which is shown in below Figure 73.

 

Figure 73-TH Created for that Node.

• In the Entity IDs option,Select the Node which is shown in below Figure 74.

 

Figure 74-Node Selected.

 

Phase 9-Create rigid wall with friction 0.1 :

 

• Here we have to create cylindrical rigid wall,Cause this side pole crash,So.
• To create Rigid Wall,Right Click on Solver Browser >> Create >> RWALL >> CYL.Which is shown in below Figure 75.

Figure 75-Creation of RWALL.

• Next we have to create a temp node on the car door to make a cylindrical rigid wall.
• After creating a temp node,Translate that node to the 300 mm.
• After translating a node,In the RWALL parameter window,We have to select (XM,YM,ZM).It is selcted by,Clicking on the node which was translated which is shown in below Figure .
• And the few parameters such as Friction, diameter of the cylindrical pole (Rigid), Searching tolerance(Dsearch) should be given which is shown in  below Figure.

 

1) Create a Temp Node which is shown in below Figure 76.

 

Figure 76-Temp Node Created.

 

2) Translate the Node which is shown in below Figure 77.

 

Figure 77-Node Translated.

 

3) Now for XM,Select the Node Translated which is shown in below Figure 78.

 

Figure 78-Selecting the Node for XM.

 

4) Now for Normal,In the Z axis,Give the value as 1 which is shown in below Figure 79.

 

Figure 79-Give the Normal Value in Z axis as 1.

 

5) Now give the values for all the parameters which is shown in below Figure 80.

 

Figure 80-Give the Values for all the Parameters.

 

6) Here increase the value of ZM to 1500 to increase the height of the rigid pole to the car's height which is shown in below Figure 81.

 

Figure 81-Increased the Height of the Pole.

 

Phase 10-Request TH File for the Required Outputs and Give Time Step Value :

• Here the timestep should be assigned to the model to run the simulation.
• The required values to be entered in the ENG_DT_BRICK,ENG_DT_INTER,ENG_DT_NODA control cards which is shown in below Figure 82.

 

Figure 82-Values Entered in ENG_DT_BRICK,ENG_DT_INTER,ENG_DT_NODA Control Cards.

• Next the TH should be requested for the Interfaces,Sections,Intrusions [Springs].

TH for Interface :

• Second request TH for the Interface,To request TH for Interface,Right Click on the Solver Browser >> Create >> TH >> INTER.Which is shown in below Figure 83.

 

Figure 83-Requesting TH for Interface.

 

• Next at the bottom,there will be a window,there go to the Entity IDs option and select the groups,A window will pop up,Select all and hit on ok.Which is shown in below Figure 84.

 

Figure 84-TH for Interface Created.

 

TH for the Sections :

• Similarly create the TH for sections as created for previous case.Which is hown in below Figures 85 and 86.

 

Figure 85-Requesting TH for Sections.

 

Figure 86-TH Created for the Sections.

 

TH for the Intrusions (Springs) :

• Similarly create the TH for Springs as created for previous case.Which is shown in below Figures 87 and 88.

 

Figure 87-Requesting TH for Springs.

 

 

Figure 88-TH Created for the Springs.

 

Phase 11-Checks :

• Finally,After doing all the load case setup,We have to check for the errors,Whether every load case setup is fine or not.
• To check,Go to Tools >> Model Checker >> Radioss Block.Which is shown in below Figure 89.

 

Figure 89-Tools Bar.

• Next the model checker window will be open which is shown in below Figure 90.
• There right click on the browser and click run or hit on green check mark in the window,which will run and identify if the error exsist in the model load case setup.

 

Figure 90-Model Checker Window.

 

Figure 91-Error in Load Case Set-Up.

• To fix the error shown in above  Figure 91.
• Isolate that error which is shown in below Figure 92,and see where the error has occured.The error occure is shown in below Figure 93.

 

Figure 92-Error Isolated.

• To fix the error which is shown in below Figure 91.To fix this delete the 1D rigid element to fix this error which is shown in below Figure 93.

 

Figure 93-Delete the 1D Rigid Element.

 

Figure 94-Error Solved.

 

Phase 11-Run the Simulation :

• Now run the simulation,To run simulation,Go to Analysis Panel as shown in below Figure 95.
• Go to Analysis Panel >> Radioss >> Select the Input File >> Save it in Different Folder and Rename it as Test-1 >> Run.
• Check the Include Connectors,If there are any connectors in the model,The connectors will also be taken into account.
• Type -NT 4 in options tab,This will make the simulation faster.
• Where NT indicates No of threads,4 indicates assigning the task to 4 cores in the system.

 

Figure 95-Analysis Panel.

 

Figure 96-Radioss Sub-Panel.

 

• After completing the simulation,the radioss will pop up a solver window stating Radioss Job Completed which indicates the simulation has been completed.
• Here the number of animation steps obtained  are shown in below Figure 97.

 

Figure 97-Animation Files Obtained.

• Now go and open the 00001.out file with notepad.
• The obtained values for Energy Error,Mass Error,Internal Energy Error,Kinetic Energy Error and Contact Energy Error has been shown in below Figure 98.

 

Figure 98-Obtained values for Energy Error,Mass Error,Internal Energy Error,Kinetic Energy Error and Contact Energy Error.

• The time taken to complete the simulation and the elapsed time is shown in below Figure 99.

 

 

Figure 99-Time Taken to Copmlete the Simulation and Elapsed Time.

 

Phase 12-Post Processing :

1) Review the Simulation using -HyperView.

2) Plot the graphs using -Hypergraph 2D.

 

1) Review the Simulation using HyperView :

• Hyperview allows for loading and viewing result files obtained from several sources.
• Based on the solver type of the files and the results you would like to visualize and analyze,there are differnt ways to load the input deck and their corresponding results into hyperview.
• First to begin the postprocessing in the Hypermesh,Split the Screen as shown in below Figure 100.
•  Import the animation file .h3d into the hyperview.

 

Figure 100-Splitting the Screen.

 

Figure 101-Screen Splitted into Two.

• And then activate the Client HyperView

Figure 102-HyperView Panel.

 

• To access the load model panel
• Select Load Model Button from the HyperView Panel and open .h3d file as shown in below Figure 103.

Figure 103-Opening .h3d File.

 

Figure 104-Model Loaded.

• After loading the model into hyperview,It will be represented as shown in below Figure 105.

Figure 105-Model Imported into HyperView.

• After importing the .h3d file into the GUI,Enable the contour.
• The contour tool create contour plots of a model graphically visualize the analysis results.
• To enable contour,Go to Results ToolBar >> Contour .

 

Figure 106-Contour Panel.

 

• Now switch to the Von Misses Stress in result type and select the component,select the averaging method as simple and then click apply as shown in below Figure 107.

 

Figure 107-Selecting the Paremeters in Contour Panel.

 

• After applying ,Run the Simulation,The Simulation animation in terms of Elements,Von Misses Stress and Displacement is shown in below Figure 108,109 and 110.

Figure 108-In Terms of Elements Animation.

Figure 109-Displacement Simulation Animation.

 

• Here the contour plot displays the displacement of each node of the BIW model of a car in a GUI.
• Displacements are computed with respect to the global co-ordinate system.
• As the model crashes into the rigid pole,the deformation occurs to each nodes and the nodes gets displaced from their initial position.
• During the simulation,maximum displacement occured at node 190233 which is shown in above Figure 113.

 

Figure 110-Von Misses Stress Simulation Animation.

 

• Here the contour plot gives the stress induced at each node in the BIW model of the car.
• As the model crashes,internal stress is developed in the model due to the material behaviour.
• During this simulation,The maximum stress developed at each node is 23242 which is shown in above Figure 110.

 

 Check for the Intrusions :

• After running the simulation,We have to check for the intrusions.
• Note :The allowable intrusion is 15 cm.
• To check for the intrusion,Measure the distance between the springs where we created.
• To measure,Go to Measure tool which is shown in below Figure 111 from HyperView and select the end node of the springs to know the distance between them,which is shown in below Figure 112 and 113.

 

Figure 111-Measure Tool.

 

Figure 112-Measuring the Intrusion at Initial Position.

 

• After defining the nodes at the end of the spring at the initial position before the collision,The magnitude for the spring is 1403.745 mm.

 

Figure 113-Measuring the Intrusion After Collision.

 

• After defining the nodes at the end of the spring after the collision,The magnitude for the spring is 1127.234 mm.

 

 Intusion at Fuel Tank Region :

 

 

Figure 114-Intrusion at Fuel Tank Region.

•  Intrusion [Spring] at Fuel Tank Region is 1403.745-1127.234 = 276.511 mm.

 

Intusion at B-Pillar Region :

 

 

Figure 115-Intrusion at B-Pillar Region.

 

•  Intrusion [Spring] at B-Pillar Region is 1335.215-929.125 = 406.09 mm.

 

 Intusion at Hinge-Pillar Region :

 

Figure 116-Intrusion at Hinge-Pillar Region.

• Intrusion [Spring] at B-Pillar Region is 1325.657-1272.834 = 52.83 mm.

 

Plot the graphs using -Hypergraph 2D :

• Now plot the graphs using Hypergraph 2D,We are plotting the graphs to see what is happening in the rail component.
• Hypergraph 2D is a powerful data analysis and plotting tool with interfaces to many popular file formats.
• It is sophisicated math engine capable of processing even the most complex mathematical expressions.
• Hypergraph 2D combines these features with high quality presentation output and customization capabilities to create a complete data analysis system for any organization.

 

Figure 117-Switching to Hypergraph 2D.

 

• Here switch to the Hypergraph 2D to plot the graphs.
• To switch,Go to Client Selector >> Choose the Hypergraph 2D as shown in above Figure 117.

• [Note : Before plotting the graphs,Make sure to split the screen into three or four and then plot the graphs.]

• The first graph is plotted for the Righ Rail at the created section.

• To plot the graph,Go to Hypergraph 2D >> Data File >>Frontal_CrashT01 >> Apply.

 

Intrusion Graph for Fuel Tank Region :

• Here the graph is obtained for the Fuel Tank region which is shown in below Figure 118.
• In the beginning,the length of the spring was 1403.74 mm and after when the car crash the pole,the length of the spring is 1127.23 mm.So the total deflection of the spring is 276.511 mm.

 

 

Figure 118-Intrusion Graph for Fuel Tank Region.

 

Intrusion Graph for B-Pillar Region :

• Here the graph is obtained for the B-Pillar region which is shown in below Figure 119.
• In the beginning,the length of the spring was 1335.21 mm and after when the car crash the pole,the length of the spring is 929.125 mm.So the total deflection of this spring is 406.09 mm.

 

 

Figure 119-Intrusion Graph for B-Pillar Region.

 

Intrusion Graph for Hinge-Pillar Region :

• Here the graph is obtained for the Hinge-Pillar region which is shown in below Figure 120.
• In the beginning,the length of the spring was 1325.66 mm and after when the car crash the pole,the length of the spring is 1272.83 mm.So the total deflection of this spring is 52.83 mm.

 

Figure 120-Intrusion Graph for Hinge-Pillar Region.

 

Peak Velocity :

• The graph obtained for the peak velocity is shown in below Figure 121.

 

 

Figure 121-Peak Velocity Graph.

 

• When the car hits the pole,the door will be deformed,So due to the deformation,the inner portion of the door will hit the passengers inside the car and it may cause severe injuries to the passengers.
• So it is important to calculate the peak velocity at the door region.
• The peak velocity of the node on the door is 9.51m/s.The graph is in Zig-Zag form,Due to the noise and vibration,When the the car hits the pole.
• Here the the velocity is starting from peak due to the initial velocity is given and it goes on decreasing,cause the car goes and hits the pole,due to deformation,itse decreasing.
• We gave the initial velocity as 8.94 m/s,But in the graph,the initial velocity is 9.51 m/s,It's increased little bit,Because due to inertia.

Interface [TYPE 7] :

• The graph obtained for the Type 7 - Total Resultant Force Interface is shown in below Figure 122.
• Here the interfaces curve starts from origin and reaches peak due to collision.
• And it increases & decreases before it reaches to peak value,Cause there will be a contact forces acting with in the car before collision.

 

Figure 122-Type 7 Contact Interface Graph.

 

Sectional Force at Cross Member 1 :

• The graph obtained for the Sectional Force at Cross Member 1 which is shown in below Figure 123.
• The maximum sectional force on the Cross Member 1 is 3.11726 KN.

 

 

Figure 123-Sectional Force at Cross Member 1.

 

Sectional Force at Cross Member 2 :

• The graph obtained for the Sectional Force at Cross Member 2 which is shown in below Figure 124.
• The maximum sectional force on the Cross Member 2 is 4.38827 KN.
• Here the sectional force is more than the Cross Member 1.

 

 

Figure 124-Sectional Force at Cross Member 2.

 

Sectional Force at Cross Member 3 :

• The graph obtained for the Sectional Force at Cross Member 3 which is shown in below Figure 125.
• The maximum sectional force on the Cross Member 3 is 0.881435 KN.
• Here for this Cross Member,the sectional force is very low when compared to the previous two Cross Members.

 

 

Figure 125-Sectional Force at Cross Member 3.

 

 Variation in Sectional Forces :

 

Figure 126-Variation in Sectional Forces.

 

All Energies :

 

• All the energies have been plotted which is shown in below Figure 127.

 

Figure 127-All Energies Graph.

 

Kinetic energy: 

• The graph obtained for kinetic energy is shown in below Figure 128.

 

Figure 128-Kinetic Energy Graph.

• Kinetic Energy is at peak in the starting,Why because,we have huge mass.
• Kinetic energy is lower and decreases,why because,there is a velocity applied to the car component,so its getting deformed and the kinetic energy decreases.
• The kinetic energy will decrease due to the decrease in velocity after the collison,When the car hits the rigid pole. So,the kinetic energy decreases with respect to time.

 

Internal Energy :

• The graph obtained for internal energy is shown in below Figure 129.

 

Figure 129-Internal Energy Graph.

• The formula for Internal Energy is I.E = Q`pm`W.
• Here the heat is neglected,Cause there is no heat transfer,We will be having only workdone.
• W=FxD
• F=ma
• Here the internal energy is in Zero,Because there is no deformation initially,So the internal energy is in Zero and starts from Zero and goes on increasing.
• The internal energy increases because the deformation is happening,there is a displacement,So the internal energy increases,when the displacement or deformation occurs.

 

Contact Energy :

• The graph obtained for Contact Energy is shown in below Figure 130.

 

Figure 130-Contact Energy Graph.

• Here the contact energy starts from origin,Cause the Car is in intial condition.
• Intially there is no contact between the Car and Rigid Pole.
• There is also no deformation intially,But when the car goes and hits on the rigid pole,The contact energy starts increasing.
• When the deformation or displacement happens to the car,the contact energy increases,cause the car component comes within the contact to the rigid pole.So the contact energy goes on increasing.

 

Total Energy :

• The graph obtained for Total Energy is shown in below Figure 131.

 

Figure 131-Total Energy Graph.

• Total Energy is sum of Kinetic Energy+Contact Energy+Hourglass Energy + Internal Energy.
• Here total energy starts from higher value,In starting itself its increasing,Why because the total energy is sum of  Kinetic Energy+Contact Energy+Hourglass Energy + Internal Energy.
• All energies are in initial condition except kinetic energy,So kinetic energy is only there
• Total Energy=Kinetic Energy+0+0+0.
• Kinetic enrgy is directly proprtional to the total energy.
• So the total energy is increasing in the beginning.
• Due to -1.8% of energy error,the total energy is decreasing.

 

Figure 132-Energy Error.

 

Hourglass Energy :

• The graph obtained for Hourglass Energy is shown in below Figure 133.

 

Figure 133-Energy Error.

[Note: Hourglass Energy should be less than 10% of Internal Energy.]

• Here the hourglass energy is less than 5% of internal energy, So it is fine.

 

Final Image :

Figure 134-Final Image.

 

Result :

• Hence the COG from the initial position has been changed to the required position by mass balancing.
• Hence the penetrations and intersections has been verified successfully.
• Hence the interfaces created newly.
• Hence the peak velocity has been given to the inner node of the doo.
• Hence the initial velocity was assigned.
• Hence the springs were created to obtain the intrusions.
• Hence the rigid pole was created successfully.
• Hence the TH for all inputs were created inorder to obtain outputs.
• Hence the simulation was runned successfully without any errors.
• Atlast all the graphs were plotted with the obtained results. 

   

Conclusion and Learning Outcome :

`***`In this Challenge,I came to know about 

• How to change the COG position.
• How to check for the penetrations and intersections.
• How to create the interfaces and how to find connectivity,To check whether the free parts exsist in the component.
• How to give Peak Velocity of inner node of the door.
• How to assign the initial velocity.
• How to create the springs to obtain intrusions.
• How to create a rigid pole according to FMVSS 214 Standards.
• How to request outputs.
• Learned about the FMVSS[Federal Motor Vehicle Saftey Standards] 214.
• Learned about the sectional forces,axial forces.