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Crash Simulation Workshop 5 : Modelling Materials in Engineering

Automotive Crash Structures

Presentation · September 2006

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 5th CRASH TECHNOLOGY GUILD WORKSHOP
7th September 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 7th September 2006 2

 AGENDA – 5th Crash Technology Guild

1. Benchmarking material suppliers raw DP600 tensile data at lower

strain rates

2. Processes to transform raw strain rate data to create material card /

benchmark with FoE and suppliers

3. Review results of crush modelling case study by consulting suppliers

4. Development of improved high speed tensile test procedures

5. Plan for bend-impact test – feed back from FoE

6.Documentation – describe workbook report format suggested by JLR

7. Review updated project timing plan

8. Agenda topics for 6th Crash Guild - validation of Aluminium strain

rate data (material cards and crush data)

© 2006 IARC

Sensitivity: Internal 7th September 2006 3

 Project Aim

Develop processes to generate and validate strain rate material

data for use in crash design models

Technical Deliverable
❑ develop code of practice for premium automotive vehicles
❑ data generation and implementation ready material models

Research Methodology
❑ establish a collaborative partnership with suppliers
❑ develop test procedures and specimen designs for high rate
data generation
❑ develop validation techniques

© 2006 IARC

Sensitivity: Internal 7th September 2006 4

 Processes to Create Material Card
Raw Engineering Stress Strain Data
900

Generate High Speed Tensile Data

Stress [MPa]
Design range of interest for crash structures is <0.001/s
1.2/s closed loop (a)
1.2/s closed loop (b)

0.001/s to 500/s 6.4/s closed loop (a)

6.4/s closed loop (b)
65/s open loop (a)
65/s open loop (b)
168/s open loop

0
0 5 10 15 20 25 30

Strain [%]

RAW TRUE DATA

1000

Data Characterisation

True Stress (Mpa)

Prepare raw data to fit surface model for use in 0.001 /s
1.2 /s
1.2 /s

crash simulation design software 6.4 /s

6.4 /s
65 /s
65 /s
168 /s
420 /s

0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18

True Plastic Strain

DP600 strain rate flow curves with IARC fitted surface

Fit Surface Model

True Stress (MPa)

Robust model fitting technique to create family of
strain rate curves
*MAT_PIECEWISE_LINEAR_PLASTICITY 0
$ DP600 steel from Arcelor (1.5 mm) - Closer0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20

True Plastic Strain

$ MID Density E Poisson'sR YieldStress
Format Material Card $
2 7.85E-9 210000.0
MAT_CL_YIELD
0.3 362.26 0.0 0.0 0.0
$SR Param C P LC (Load curve or table ID)
For use in crash simulation design software 0.0
0.0
0.0
0.0
611
0.0
0
0.0
0.0
0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
$
*DEFINE_TABLE
© 2006 IARC

Sensitivity: Internal 7th September 2006 5

 Validation Processes

▪Benchmark suppliers data

▪Develop component tests

© 2006 IARC

Sensitivity: Internal 7th September 2006 6

 Early Raw Engineering Test Data

800

600
Stress (Mpa)

400

Quasi-Static (25MPa/s until yielding)

200
Dynamic (66/s, 2-15%)
Dynamic (420/s, 8-11.5%)

0
0 5 10 15 20 25 30
Strain (%)
© 2006 IARC

Sensitivity: Internal 7th September 2006 7

 New Raw Engineering Test Data

800
Engineering stress (MPa)

600

<0.001/s
1.2/s closed loop (a)
400 1.2/s closed loop (b)
6.4/s closed loop (a)
6.4/s closed loop (b)
65/s open loop (a)
200 65/s open loop (b)
168/s open loop
420/s open loop

0
0 5 10 15 20 25 30
Engineering Strain (%)
© 2006 IARC

Sensitivity: Internal 7th September 2006 8

 Preparing Raw Data for Benchmarking

900
800
700
True stress (MPa)

600 0.001 /s
500 1.2 /s
1.2 /s
400 6.4 /s
6.4 /s
300 65 /s
200 65 /s
168 /s
100 420 /s

0
0 0.05 0.1 0.15 0.2
True plastic strain
© 2006 IARC

Sensitivity: Internal 7th September 2006 9

 Issues Arising with Machine Controls

Raw Engineering Stress Strain Data

900

800

700

600
Stress [MPa]

500

400
6 to 7 kHz
<0.001/s
300 1.2/s closed loop (a) test speed 0.08m/s
1.2/s closed loop (b) test speed 0.08m/s
200 250 Hz 6.4/s closed loop (a) test speed 0.5m/s
6.4/s closed loop (b) test speed 0.5m/s
65/s open loop (a) test speed 5m/s
100 65/s open loop (b) test speed 5m/s
168/s open loop test speed 6m/s
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Strain [%]
© 2006 IARC

Sensitivity: Internal 7th September 2006 10

 Benchmarking Suppliers Raw Test Data

Dr. I. McGregor
Corus Automotive

© 2006 IARC

Sensitivity: Internal 7th September 2006 11

 Data Transformation Processes to Create
Material Card
Pre-processing
Determine yield point for each raw engineering strain rate flow curve

Remove elastic strain from raw engineering flow curve (offset flow curve on strain axis) to
create plastic engineering strain

Convert engineering plastic data to true plastic data and remove data after maximum tensile
strength; maximum tensile strength is determined from the raw engineering flow curve (we
are only interested in uniform tensile elongation)

Curve fitting
Fit Power Law to each curve;
- add theoretical elastic strain to plastic strain to give total strain
- take natural log of both stress and strain from yield strain onwards
- determine both slope and intercept (these are the power law coefficients)

Fit surface model to each curve

- plot natural log (n) versus strain rate and determine power law coefficients as
function of strain rate
- do similar for k and note k is independent of strain rate

Format Model to Create Material Card

© 2006 IARC

Sensitivity: Internal 7th September 2006 12

 Pre-Processing – Determine Yield
Raw Engineering Stress Strain Data
800

700

600

500
Stress [MPa]

400

300 <0.001/s
1.2/s closed loop (a)
200
1.2/s closed loop (b)
6.4/s closed loop (a)
6.4/s closed loop (b)
100
65/s open loop (a)
65/s open loop (b)
0 168/s open loop
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

-100

-200

0.2 % Strain Offset Strain [%]

© 2006 IARC

Sensitivity: Internal 7th September 2006 13

 Pre-Processing – Determine Yield
Raw Engineering Stress Strain Data
Slope = Young’s Modulus
800

700

600

500
Stress [MPa]

400

300 <0.001/s
1.2/s closed loop (a)
200
1.2/s closed loop (b)
6.4/s closed loop (a)
6.4/s closed loop (b)
100
65/s open loop (a)
65/s open loop (b)
0 168/s open loop
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

-100

-200

Strain
Theoretical [%]Strain
Elastic
© 2006 IARC

Sensitivity: Internal 7th September 2006 14

 Fitting Curve to Quasi-static Data

8
7
6
Ln (true stress)

5
4
y = 0.177x + 6.954 s = k[e0 + e] n
k = 1047
R2 = 0.9993 3
n = 0.177
2
1
0
-8 -6 -4 -2 0
Ln (true plastic strain)
© 2006 IARC

Sensitivity: Internal 7th September 2006 15

 Fitting Curve to Strain Rate Data (65/s)

8
7
6
Ln (true stress)

5
y = 0.1926x + 7.1424 4
R2 = 0.9886
s = k[e0 + e] n k = 1264 3
n = 0.193
2
1
0
-8 -6 -4 -2 0
Ln (true plastic strain)
© 2006 IARC

Sensitivity: Internal 7th September 2006 16

 Fitting Curve to Strain Rate Data (420/s)

8
7
6
Ln (true stress)

y = 0.136x + 7.019 4
R2 = 0.4882 s = k[e0 + e] n k = 1117 3
n = 0.136
2
1
0
-8 -6 -4 -2 0
Ln (true plastic strain)
© 2006 IARC

Sensitivity: Internal 7th September 2006 17

 Compare Model to Test Data
Quasi-static flow curve with fitted model Strain rate flow curve at 6.4/s with fitted model
1000 1000

800 800

True Stress (MPa)

True Stress (MPa)

600 600

Experimental Experimental
400 400 Fitted Model (least squares)
Fitted Model (least squares)

200 200

0 0
0.00 0.05 0.10 0.15 0.20 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16

True Plastic Strain True Plastic Strain

Strain rate flow curve at 420/s with fitted model

Strain rate flow curve at 65/s with fitted model
1000
1000

800
800

True Stress (MPa)

True Stress (MPa)

600 600

Experimental Experimental
400 400 Fitted Model (least squares)
Fitted Model (least squares)

200 200

0 0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0 0.02 0.04 0.06 0.08 0.1 0.12
True Plastic Strain True Plastic Strain

© 2006 IARC

Sensitivity: Internal 7th September 2006 18

 Develop Surface Model – Determine n = f(e)
(stress, strain & strain rate dependency)

0.0
-8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
-0.5
y = -0.011x - 1.736
-1.0 n = k1[e] m
Ln(n)

k1 = 0.176
-1.5 m = - 0.011

-2.0

-2.5
Ln (true strain rate)

© 2006 IARC

Sensitivity: Internal 7th September 2006 19

 Develop Surface Model – Determine k = f(e)
(stress, strain & strain rate dependency)

8.0
7.0
6.0
5.0
ky==constant
0.0093x + 7.039
Ln(k)

k=1160 (averaged data)

4.0
3.0
2.0
1.0
0.0
-8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Ln (true strain rate)
© 2006 IARC

Sensitivity: Internal 7th September 2006 20

 Expressions used to Create Surface Model

s = k[e0 + e] n

n = k1[e] m

k = Constant
© 2006 IARC

Sensitivity: Internal 7th September 2006 21

 Fit Surface Model – Compare with Test Data

Corus DP600 strain rate flow curves with IARC fitted surface
1000

900
IARC fitted surface 0.001/s
800 IARC fitted surface 1.2/s
True Stress (MPa)

IARC fitted surface 6.4/s

IARC fitted surface 65/s
700 IARC fitted surface 168/s
IARC fitted surface 420/s
IARC raw test data 0.001/s
600 IARC raw test data 1.2/s
IARC raw test data 1.2/s
IARC raw test data 6.4/s
500 IARC raw test data 6.4/s
IARC raw test data 65/s
400 IARC raw test data 65/s
IARC raw test data 168/s
IARC raw test data 420/s
300
0.00 0.05 0.10 0.15 0.20
True Plastic Strain
© 2006 IARC

Sensitivity: Internal 7th September 2006 22

 Compare Fitted Surface Models

Compare IARC and BERGSTROM surface fits

1000

900 IARC fitted surface 0.001/s

IARC fitted surface 1.2/s
True Stress (MPa)

800 IARC fitted surface 6.4/s

IARC fitted surface 65/s
700 IARC fitted surface 168/s
IARC fitted surface 420/s
600 IARC Berg1 0.001/s
IARC Berg1 1.2/s
IARC Berg1 6.4/s
500
IARC Berg1 65/s
IARC Berg1 168/s
400 IARC Berg1 420/s

300
0.00 0.05 0.10 0.15 0.20

True Plastic Strain

© 2006 IARC

Sensitivity: Internal 7th September 2006 23

 Compare Fitted Surface Models

Compare IARC and FoE surface fit for strain rate flow curves

1000

900 IARC fitted surface 0.008/s

IARC fitted surface 1.6/s
True Stress (MPa)

800 IARC fitted surface 5.8/s

IARC fitted surface 22/s
700 IARC fitted surface 80/s
IARC fitted surface 300/s
600 FoE 0.008/s
FoE 1.6/s
FoE 5.8/s
500
FoE 22/s
FoE 80/s
400
FoE 300/s

300
0.00 0.05 0.10 0.15 0.20

True Plastic Strain

© 2006 IARC

Sensitivity: Internal 7th September 2006 24

 Compare Surface Models at High Strain

Compare IARC and FoE surface fit for strain rate flow curves

1400
IARC fitted surface 0.008/s
1200 IARC fitted surface 1.6/s
IARC fitted surface 5.8/s
True Stress (MPa)

IARC fitted surface 22/s

1000 IARC fitted surface 80/s
IARC fitted surface 300/s
800 FoE 0.008/s
FoE 1.6/s
FoE 5.8/s
600
FoE 22/s
FoE 80/s
400 FoE 300/s

200
0.00 0.50 1.00 1.50 2.00

True Plastic Strain

© 2006 IARC

Sensitivity: Internal 7th September 2006 25

 Formatted IARC Material Card with
Strain Rate Dependency
*MAT_PIECEWISE_LINEAR_PLASTICITY *DEFINE_TABLE
$ DP600 Arcelor steel (1.5 mm) $
$ MID Density E Poisson'sR YieldStress 601
$ MAT_TH_YIELD $
1 7.85E-9 210000.0 0.3 362.26 0.0 0.0 0.0 $ List of factors:
$SR Param C P LC (Load curve or table ID) $
0.0 0.0 601 0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.01
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.10
*DEFINE_CURVE 1.00
$ 1 ][ 2 ][ 3 ][ 4 ][ 5 ][ 6 ][ 7 ] 10.0
602 0 1.0 1.0 0.0 0.0 0 100.0
0,362.256099 1000.0
0.001,375.5226959
0.002,387.174709
FoE ~ 40 co-ordinates
0.003,397.5972918 IARC ~ 400 co-ordinates
0.004,407.0491691

© 2006 IARC

Sensitivity: Internal 7th September 2006 26

 Formatted FoE Material Card with Strain
Rate Dependency
*MAT_PIECEWISE_LINEAR_PLASTICITY_TITLE *DEFINE_TABLE
DP600 $ Cross-reference
9148000
148000 7.8E-9 205000.0 0.3 352.4 0.0 0.0 0.0
$ List of factors:
0.0 0.0 9148000 0 0.0
$
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
8.0000004E-3
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
2.9840000E-2
*DEFINE_CURVE
0.11130000
$ Cross-reference summary for Load-curve 9148001
0.41530001
$
1.5490000
9148001 0 1.0 1.0 0.0 0.0 0
5.7789998
0.0 352.39999
21.559999
4.9999999E-3 406.51001
80.420013
9.9999998E-3 453.67999
300.00000
1.5000000E-2 493.85001
2.0000000E-2 527.85999
2.5000000E-2 556.56000 FoE ~ 40 co-ordinates
2.9999999E-2 580.82001
3.5000000E-2 601.48999
IARC ~ 400 co-ordinates
3.9999999E-2 619.40997

© 2006 IARC

Sensitivity: Internal 7th September 2006 27

 Component Validation

DYNAMIC CRUSH DATA

200
180
160
Crush Force (kN)

140
120
100
80
60
40
20
0
0 20 40 60 80 100 120 140 160 180 200

Crush Displacement (mm)

© 2006 IARC

Sensitivity: Internal 7th September 2006 28

 Component Validation

COMPARE QUASI-STATIC AND DYNAMIC CRUSH DATA

180
DYNAMIC (MEDIUM
160 RESULT)
QUASI-STATIC
140
Crush Force (kN)

120
100
80
60
40
20
0
0 20 40 60 80 100 120 140 160 180 200

Crush Displacement (mm)

© 2006 IARC

Sensitivity: Internal 7th September 2006 29

 Strain Rate Switched On and Off

Compare simulated crush results with strain rate dependency switched

on and off

150000 EXPERIMENT DATA (SLED IMPACT)

SIMULATED CRUSH IARC MAT CARD (no_strainrate)
SIMULATED CRUSH IARC MAT CARD (strainrate_on)
125000

100000
Force (N)

75000

50000

25000

0
0 20 40 60 80 100 120 140 160 180 200

Displacement (mm)

© 2006 IARC

Sensitivity: Internal 7th September 2006 30

 Comparing Material Cards in Dynamic Crush
Models
Compare crush results using different material cards
200000
EXPERIMENTAL DATA (SLED IMPACT) MID-RESULT
175000 SIMULATED - FoE MATERIAL DATA

SIMULATED - IARC MATERIAL DATA

150000
SIMULATED - BERG FITTED TO IARC HIGH RATE TENSILE
DATA
125000
Force (N)

100000

75000

50000

25000

0
0 20 40 60 80 100 120 140 160 180 200

Displacement (mm)

© 2006 IARC

Sensitivity: Internal 7th September 2006 31

 Comparing Material Cards and Element Types
in Dynamic Crush Models
Compare crush force averages over increasing
displacement intervals
90
Experimental data (sled impact)
85 Experimental data (quasi-static)
Model FoE type 16 elem (6.5 m/s)
Model IARC no_strainrate type 16 elem (1 m/s)
displacement interval (kN)

80
Average force over crush

Model IARC no_strainrate type 2 elem (1 m/s)

Model IARC type 16 elem (6.5 m/s)
75 Model IARC type 2 elem (6.5 m/s)

70
65
60

55
50

45
40
0 to020 0 to040 0 to060 0 to 080 0 to 0100 0 to 0160

Crush displacement interval (mm)

© 2006 IARC

Sensitivity: Internal 7th September 2006 32

 Review results of crush modelling case study by
consulting suppliers
Initiator/indent on this end
of column (note spot weld
positions). Indent details
given in file initiator.hm

© 2006 IARC

Sensitivity: Internal 7th September 2006 33

 Crush models developed by consulting suppliers

© 2006 IARC

Sensitivity: Internal 7th September 2006 34

 Results of crush modelling case study done by
consulting suppliers
3.0E+05

2.5E+05

2.0E+05
Force (N)

1.5E+05

1.0E+05

5.0E+04

0.0E+00
0 30 60 90 120 150 180

© 2006 IARC
Displacement (mm)
Sensitivity: Internal 7th September 2006 35
 Results of crush modelling case study done by
consulting suppliers

100
displacement interval (kN).
Average force over crush

90
Model data
80

70
Exp - sled impact
60
Exp - quasi-static
50

40
0 to 1
20 0 to 2
40 0 to360 0 to480 0 to5100 0 to
6 160

© 2006 IARC
Crush displacement interval (mm)
Sensitivity: Internal 7th September 2006 36
 Development of improved high speed tensile
test procedures

© 2006 IARC

Sensitivity: Internal 7th September 2006 37

 Summary of Test Procedure

© 2006 IARC

Sensitivity: Internal 7th September 2006 38

 IARC Specimen Designs for High Speed Testing

Test Speed of 5 m/s (~ 80/s): Gauge length 60 mm Load-Filtered Actuator Position, Steel DP600 (2mm), Dynamic (5 m/s)

18

16

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

Test Speed of 15 m/s (~ 600/s): Gauge length 25 mm 18
(~ STRAIN RATE = 605 s-1, DAQ Frequency set to 2.5 MHz)
18

16 16

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

© 2006 IARC LVDT Actuator Position (mm)

Sensitivity: Internal 7th September 2006 39

 Modelling Test Procedures – Development of
Improved Specimen Design

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 7th September 2006 40

 Stochastic Modelling - Investigate Influence of Specimen Geometry
Variations at Test Speed 15 m/s

Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
(common)

Random Nominal Upper Bound Lower Bound Distribution Number of Independent

Variable (mm) Limit (mm) Limit (mm) Model Applied Samples
Geometric Static Grip L 34 65 34 Uniform 100
Properties Trans Radius 20 36 4 Uniform 100
Gauge L 25 40 10 Uniform 100
Gauge W 10 12.5 7.5 Uniform 100
Boundary
Grip Offset 0 35 -35 Uniform 100
Condition

Nominal design

Moving grip length

Lower bound design

Upper bound design

© 2006 IARC

Sensitivity: Internal 7th September 2006 41

 Stochastic Modelling - Investigate Influence of Specimen
Geometry Variations at Test Speed 15 m/s

Nominal Design

© 2006 IARC

Sensitivity: Internal 7th September 2006 42

 Stochastic Modelling - Investigate Influence of Specimen
Geometry Variations at Test Speed 15 m/s
Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
(common)
Difference between developed

High Variability
Stress gradient across
and target strain rate

strain gauge

© 2006 IARC

Sensitivity: Internal 7th September 2006 43

 Two modes of behaviour present in results
Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
2.2E-03
in strain gauge force sensor ( dL/L)
Maximum strain at first oscillation

(common)

2.0E-03
Yield strain exceeded
1.8E-03
Yield strain not exceeded
1.6E-03

1.4E-03

1.2E-03 Nominal design

1.0E-03
550 600 650 700 750 800

© 2006 IARC Maximum tensile engineering stress (MPa)

Sensitivity: Internal 7th September 2006 44
 Modes influenced mostly by gauge length width
Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
Maximum strain at first oscillation in

2.2E-03
strain gauge force sensor ( dL/L)

(common)

2.0E-03
Yield strain
1.8E-03
exceeded
1.6E-03

1.4E-03
Nominal design
1.2E-03

1.0E-03
6 7 8 9 10 11 12 13 14
© 2006 IARC Gauge Width (mm)
Sensitivity: Internal 7th September 2006 45
 Modes influenced mostly by gauge length
width
Datum
Grip Offset Gauge L Static Grip L

Gauge W

800 Trans Radius

Yield strain not exceeded (common)
Maximum tensile engineering

Yield strain exceeded

750 Nominal design
Max eng tensile stress of material input
(MPa)

700
stress.

650

600

550
6 7 8 9 10 11 12 13 14
© 2006 IARC
Gauge Width (mm)
Sensitivity: Internal 7th September 2006 46
 Geometry influence on amplitude of load
oscillation
Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
80 45 (common)
Static grip length
Gaugle length 40
70
Static grip length (mm)

35

Gauge length (mm)

60 30

25
50 20
15
40
10

30 5
0 50 100 150 200 250

© 2006 IARC 10 to 50 kHz (MPa)

FFT - Maximum stress amplitude in frequency range (MPa)
Sensitivity: Internal 7th September 2006 47
 Geometry influence on frequency of load
oscillation
Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
80 50 (common)
Static grip length

70 Transition radius 40

Transition Radius (mm)

Static grip length (mm)

Linear (Transition
60 radius) 30
Linear (Static grip length)

50 20

40 10

30 0
14 16 18 20 22 24 26 28 30 32

FFT - Frequency corresponding to maximum stress

© 2006 IARC
amplitude (kHz)
Sensitivity: Internal 7th September 2006 48
 Geometry influence on stress difference across
strain gauge force sensor
Datum
Grip Offset Gauge L Static Grip L

Gauge W

50 Trans Radius
(common)
Stress difference across strain gauge

40
averaged over 1 to 10% strain

30
20
10
(MPa)

0
-10 35 40 45 50 55 60 65 70 75

-20
-30
-40
-50

© 2006 IARC
Static Grip Length (mm)
Sensitivity: Internal 7th September 2006 49
 Geometry influence on developed strain rate
Datum
Grip Offset Gauge L Static Grip L

Gauge W

Trans Radius
1600 (common)
Target engineering strain rate
1400
Developed strain rate averaged
1200 over 1 to 10% strain
Strain rate (1/s)

1000

800

600

400

200 Gauge Length = 10 mm

Gauge Length = 40 mm
0
10 30 50 70 90

© 2006 IARC First natural frequency of gauge length (kHz)

Sensitivity: Internal 7th September 2006 50
 Bend-Impact test

Summary
❑ Good comparison of FEA results (strain rate model) with experimental results at strain
gauge location.
❑ Developed test procedure could be used to validate material properties in pressed
components and to test FEA models.

Evaluation of current pressing profile

❑ After impact the remaining 2nd moment of inertia is small. A ‘hinge’ is formed under the
impacter, but strains remain small due to lifting of flange.
❑ Normally, no failure develops, but profile is not representative of typical structure under
bend impact (e.g. B-post)

Planned Work
❑ Change current section to U-shaped profile with deeper section. This should increase
tensile strains at the bottom of the profile.
❑ FEA of high velocity bending experiment with new section
❑ Bend-forming of new section in aluminium and conduct experiments at suitable velocity.

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 Bending Impact Fixture

Instrumentation

Guides

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 Results for Press-Formed Top Hat Section

Effect of Velocity (Top Hat Section)

14000

12000

10000
Force [N]

8000

6000

4000
FEA Quasi Static (v = 0.05 m/s)
Experiment (v = 0.01 m/s)
2000
FEA Dynamic (v = 5 m/s)
Experiment (v = 5 m/s)
0
© 2006 IARC0 5 10 15 20 25 30 35 40 45 50
Displacement [mm]
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 New Sections for High Velocity Bending under
Impact

700

Similar to High tensile

B post strains

500

© 2006 IARC

Sensitivity: Internal 7th September 2006 54

 Strains across profiles

70

Similar to
B post
70

60

High tensile
strains
60

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 Constraining U-section

Type Problem Advantage

A) Profile slides Friction Quick set up of

between blocks Experiment

B) Blocks fixed Inertia of moving Easy to produce

To profile Mass

C) Profile and High side loads Highest tensile strain

blocks fixed at
both ends

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 Failure mode analysis
Repeatability of failure

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© 2006 IARC

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 Reduction of Indentation?

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 Summary

Objectives:
Consult other labs regarding geometry and suitable constraints.
FEA of high velocity experiment with U section.
Bend forming of U section in aluminium.
Manufacturing of constraints.
High velocity testing with bending fixture.
Failure mode analysis.

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Sensitivity: Internal 7th September 2006 60

PARD Materials Characterisation and Simulation Project Time Plan for 2006 (Update 23rd May 2006)
2006 Risk of delivery
Task January February March April May June July August failure
1. DP600
2. NG 5754
Crush testing
3. AC300
Verify test specification (e.g. position of spot welds) 4. DX56D
Establish/Procure all materials (total 20 tests)
Fabricate & join specimens (JLR)
Simulated paint bake (aluminium specimens) new activity
Prepare specimens for testing
Quasi-static test (aluminium specimens NG5754 and AC300) offsite testing
High speed test (aluminium specimens NG5754 and AC300) offsite testing Mid October
Analysis of data 2006
Component tests

Report

Compression bend/impact 1. DP600

Training (phase 2) - define requirements & implement 2. NG 5754
Test shear pin failure load? 3. AC300
Instrument impactor and calibrate 4. DX56D
Develop test specification (for different test speeds)
Establish/Procure material (total 52 tests)
Manufacture specimens (Premier Sheet Metals)
Prepare specimens for testing 1 2 3 4
Low speed or quasi-static test
End
High speed test
December
Analysis of data
2006
Report

High speed tensile tests 1. DP600

Data characterisation at high

Order new jaw faces 2. NG 5754

Refine test procedures (calibrate specimens) 3. AC300
4. DX56D
Establish/Procure material (total 75 tests to include calibration)
strain rate

Manufacture specimens (internal)

Simulated paint bake (aluminium specimens) new activity
Prepare specimens for testing 1 2 3 4
Refine
Quasi-static test End
High speed test December
Create material card 2006
Report

Document Test Specifications (recommendations)

Materials
Mat 1 DP600
Mat 2 DX56D (mild steel - low JLR priority)
© 2006 IARC Mat 3 AC-300
Mat 4 NG 5754
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 Agenda topics for 6th Crash Guild –
validation of Aluminium strain rate data
(material cards and crush data)

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