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Python Tools for Crash CAE Model Preprocessing

30 Chapters

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Crash CAE model preprocessing landscape

role of Python in LS-DYNA, Pam-Crash, and Radioss workflows, common bottlenecks, and automation opportunities.

CAEpreprocessing

Python environment for CAE preprocessing

installing Anaconda, managing packages with conda and pip, and configuring IDEs for large model scripts.

Core Python data structures for CAE

lists, dictionaries, NumPy arrays, and pandas DataFrames for node, element, and part metadata.

Reading and writing LS-DYNA keyword files

parsing *NODE, *ELEMENT, *PART, and *SET cards with Python file I/O and regular expressions.

Mesh data extraction and manipulation

using PyVista and VTK to read NASTRAN, STL, and OBJ files, and to query node coordinates and element connectivity.

extractionmanipulation

Automated model cleanup

detecting and removing duplicate nodes, degenerate elements, and free edges with Python scripts and mesh quality metrics.

Automateddetecting

Geometry preparation for crash simulation

importing CAD via STEP and IGES using pythonocc or CadQuery, and simplifying for shell meshing.

Geometrypreparation

Shell meshing automation

generating 2D meshes with Gmsh Python API, controlling element size, and exporting to LS-DYNA format.

automationgenerating

Solid meshing for crash components

creating hexahedral and tetrahedral meshes with Gmsh and pyvista, and mapping to *ELEMENT_SOLID cards.

componentscreating

Material model assignment

parsing material cards (*MAT_ELASTIC, *MAT_PLASTIC_KINEMATIC, *MAT_CRUSHABLE_FOAM) and applying them to part sets via Python.

Materialassignment

Section property definition

automating *SECTION_SHELL and *SECTION_SOLID creation from thickness maps and part metadata.

propertydefinition

Contact definition automation

generating *CONTACT_AUTOMATIC_SINGLE_SURFACE and *CONTACT_AUTOMATIC_SURFACE_TO_SURFACE cards using part sets and Python logic.

definitionautomation

Boundary condition and initial velocity setup

scripting *BOUNDARY_SPC_SET and *INITIAL_VELOCITY cards for crash load cases.

Boundarycondition

Rigid wall and barrier modeling

creating *RIGIDWALL_PLANAR and *RIGIDWALL_GEOMETRIC cards with Python for offset deformable barrier and pole impacts.

modelingcreating

Seat belt and airbag preprocessing

defining *ELEMENT_SEATBELT, *AIRBAG_SIMPLE_PRESSURE_VOLUME, and *AIRBAG_WANG_NEFSKE with Python parameterization.

preprocessingdefining

Model assembly and transformation

merging parts, applying translations and rotations with NumPy, and updating node and element IDs.

assemblytransformation

Part and set management

creating *SET_PART, *SET_NODE, and *SET_SEGMENT from geometric queries and attribute filters using Python.

managementcreating

Include file organization

structuring large crash models with *INCLUDE_TRANSFORM and Python scripts to generate modular keyword files.

organizationstructuring

Parameterization and design of experiments

using Python to generate multiple model variants for DOE and optimization studies.

Parameterizationexperiments

Model checking and validation

writing Python scripts to verify keyword syntax, check for missing properties, and detect unreferenced entities.

checkingvalidation

Mesh quality assessment for crash

computing Jacobian, aspect ratio, warpage, and skewness with Python and flagging critical elements.

assessmentcomputing

Penetration and interference checks

using PyVista and trimesh to detect initial penetrations between parts and contacts.

Penetrationinterference

Mass and inertia calculation

computing total mass, center of gravity, and inertia tensor from mesh and material data with Python.

calculationcomputing

Preprocessing for occupant safety

positioning dummy models (Hybrid III, THOR) with Python, and setting up *CONSTRAINED_NODAL_RIGID_BODY.

Preprocessingoccupant

Automation of load case setup

scripting frontal, side, and rear impact configurations with parameterized Python functions.

Automationscripting

Integration with LS-DYNA solver

generating input decks, running LS-DYNA via subprocess, and parsing d3plot results with Python.

IntegrationLS-DYNA

Workflow orchestration

building preprocessing pipelines with Snakemake or Prefect for repeatable crash model generation.

Workfloworchestration

GUI and interactive tools

developing simple GUIs with PyQt or Streamlit for preprocessing parameter input and model visualization.

Performance optimization

using NumPy vectorization, Numba, and parallel processing to accelerate large model preprocessing.

Performanceoptimization

end-to-end Python-based preprocessing of a full vehicle frontal crash model, from CAD to ready-to-run LS-DYNA deck.

end-to-endPython-based