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LS-DYNA Metal Forming History in Crash Simulation

30 Chapters
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01
Course overview
role of metal forming history in crash simulation, LS-DYNA workflow context, and engineering objectives.
simulationLS-DYNA
02
Forming-induced property changes
plastic strain, thickness reduction, residual stress, and work hardening relevant to crash response.
Forming-inducedproperty
03
LS-DYNA forming simulation fundamentals
explicit and implicit solvers, time scaling, and mass scaling for sheet metal forming.
LS-DYNAsimulation
04
Material models for forming history
*MAT_024, *MAT_037, *MAT_123, and *MAT_224 with hardening and strain-rate effects.
MaterialMAT
05
Mapping forming results to crash models
initialization of stress, strain, thickness, and history variables using *INITIAL_STRESS_SHELL and related keywords.
initializationthickness
06
Shell element formulation choices for forming and crash
ELFORM 2, 16, and 26 with hourglass control and through-thickness integration.
formulationELFORM
07
Springback simulation and its influence on crash-relevant geometry and residual stress state.
Springback simulation and its influence on crash-relevant geometry and residual stress state.
Springbacksimulation
08
One-step and multi-step forming approaches in LS-DYNA
advantages, limitations, and crash simulation fidelity.
One-stepmulti-step
09
Forming limit diagrams and failure criteria
*MAT_ADD_EROSION, *MAT_ADD_DAMAGE, and GISSMO for crashworthiness.
diagramscriteria
10
Contact and friction modeling in forming
*CONTACT_FORMING_ONE_WAY_SURFACE_TO_SURFACE and its effect on history variables.
frictionmodeling
11
Trimming and springback compensation
LS-DYNA keywords and their impact on crash model initialization.
Trimmingspringback
12
Welded and joined blank assemblies
forming history transfer for tailor-welded and tailor-rolled blanks.
assembliestransfer
13
Hydroforming and tube bending history
mapping internal pressure and axial feed effects into crash models.
Hydroforminginternal
14
Hot stamping and press hardening
thermal-mechanical forming history and its role in crash simulation.
stampinghardening
15
Incremental forming and roll forming
history mapping for continuous processes in LS-DYNA.
Incrementalcontinuous
16
Validation of forming history mapping
comparison of mapped versus as-formed properties in crash tests.
Validationcomparison
17
Case study
automotive B-pillar forming history and its effect on side impact simulation.
automotiveB-pillar
18
Case study
front rail forming history and frontal crash energy absorption prediction.
absorptionprediction
19
Case study
door beam roll forming history and bending crash performance.
performance
20
Case study
aluminum hood forming history and pedestrian impact simulation.
aluminumpedestrian
21
Numerical stability and convergence
implicit forming followed by explicit crash in LS-DYNA.
Numericalstability
22
Data transfer formats and tools
LS-DYNA binary databases, *INCLUDE_TRANSFORM, and mapping utilities.
transferLS-DYNA
23
Mesh mapping strategies
node interpolation, element mapping, and handling of adaptive remeshing.
strategiesinterpolation
24
Sensitivity and uncertainty
scatter in forming history and its propagation to crash results.
Sensitivityuncertainty
25
Performance optimization
reducing turnaround time for forming-to-crash workflows in LS-DYNA.
Performanceoptimization
26
Verification and validation metrics
correlation of forming history effects with physical crash tests.
Verificationvalidation
27
Industrial best practices
guidelines for incorporating forming history in crash simulation per OEM and Tier 1 workflows.
Industrialpractices
28
Common pitfalls
incorrect mapping, missing history variables, and element distortion issues.
pitfallsincorrect
29
Advanced topics
multi-stage forming, springback compensation, and history-dependent failure in crash.
Advancedmulti-stage
30
Capstone project
end-to-end LS-DYNA simulation of a formed component from forming through crash with history mapping.
Capstoneend-to-end