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LS-DYNA Crash Simulation Program Planning and Delivery

30 Chapters
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01
Program initiation and scoping
defining CAE deliverables, regulatory and internal targets, and stakeholder alignment for an LS-DYNA crash simulation program.
initiationdefining
02
Simulation model architecture planning
selecting unit systems, coordinate conventions, file organization, and version control for LS-DYNA crash models.
Simulationarchitecture
03
Geometry preparation and CAD cleanup
meshing strategies, midsurface extraction, defeaturing, and quality checks for crashworthiness models.
Geometrypreparation
04
Material model selection and calibration
choosing LS-DYNA material cards (MAT_024, MAT_123, MAT_187, etc.) and fitting parameters from coupon tests.
Materialselection
05
Connection modeling
spot welds, adhesives, bolts, and seams using *CONSTRAINED, *MAT_SPOTWELD, and cohesive zone methods.
Connectionmodeling
06
Contact definition and control
*CONTACT_AUTOMATIC_SINGLE_SURFACE, *CONTACT_AUTOMATIC_SURFACE_TO_SURFACE, and penalty stiffness tuning.
definitionCONTACT
07
Boundary conditions and initial velocity setup
rigid walls, prescribed motion, and initialization for frontal, side, and rear impact load cases.
Boundaryconditions
08
Load case matrix development
mapping regulatory (FMVSS, ECE, IIHS) and internal requirements to LS-DYNA simulation runs.
developmentregulatory
09
Mesh convergence and hourglass control
element size studies, *HOURGLASS settings, and energy balance verification.
convergencehourglass
10
Time step control and mass scaling
*CONTROL_TIMESTEP, selective mass scaling, and assessing inertia effects on results.
CONTROLTIMESTEP
11
Solver execution and parallelization
SMP vs MPP, *CONTROL_MPP_DECOMPOSITION, and HPC job submission for crash models.
executionparallelization
12
Simulation run monitoring and debugging
checking d3hsp, messag, and glstat files for negative volumes, initial penetrations, and instability.
Simulationmonitoring
13
Occupant safety restraint modeling
airbag (*AIRBAG), seatbelt (*ELEMENT_SEATBELT), and pretensioner/load limiter implementation.
Occupantrestraint
14
Barrier and impactor modeling
rigid wall definitions, deformable barrier (EEVC, NHTSA) setups, and moving deformable barrier (MDB) for side impact.
impactormodeling
15
Post-processing and result extraction
using LS-PrePost to generate section forces, intrusions, accelerations, and injury criteria (HIC, chest deflection).
Post-processingextraction
16
Correlation and validation with physical tests
test data filtering, objective rating methods (CORrelation and Analysis, ISO/TS 18571), and model updating.
Correlationvalidation
17
Design of Experiments (DOE) for crashworthiness
parameter screening, metamodeling (response surface, Kriging), and optimization with LS-OPT.
ExperimentsDOE
18
Robustness and reliability assessment
accounting for material scatter, manufacturing tolerances, and probabilistic simulation in LS-DYNA.
Robustnessreliability
19
Program scheduling and resource planning
estimating CPU hours, model build time, and dependencies across multiple load cases.
schedulingresource
20
Data management and traceability
organizing LS-DYNA input decks, results, and reports for audit and re-use.
managementtraceability
21
Quality assurance and checklists
peer review, model sign-off criteria, and automated QA scripts for LS-DYNA decks.
assurancechecklists
22
Reporting and communication
creating clear CAE reports, executive summaries, and design recommendations from simulation results.
Reportingcommunication
23
Delivery milestones and gate reviews
aligning simulation deliverables with vehicle program timing (e.g., prototype builds, design freezes).
Deliverymilestones
24
Handling late design changes
rapid model updates, re-running critical load cases, and impact on delivery schedule.
Handlingre-running
25
Integration with other CAE disciplines
NVH, durability, and CFD co-simulation or data exchange for multidisciplinary optimization.
IntegrationCAE
26
Advanced material modeling for crash
strain-rate effects, failure criteria (GISSMO, DIEM), and validation for high-strength steels and composites.
Advancedmaterial
27
Side impact and pole impact specifics
door trim, B-pillar, and battery pack modeling for electric vehicles.
specificsB-pillar
28
Pedestrian protection simulation
legform, upper legform, and headform impactor models and Euro NCAP requirements.
Pedestrianprotection
29
Model re-use and automation
scripting with LS-DYNA keywords, Python, and LS-PrePost command files for parametric studies.
automationscripting
30
Final program delivery and lessons learned
closing out a crash simulation program, archiving models, and capturing best practices for future projects.
deliverysimulation