Improving FEM crash simulation accuracy through local thickness estimation based on CAD data

In this paper, we present a method for estimating local thickness distribution in nite element models, applied to injection molded and cast engineering parts. This method features considerable improved performance compared to two previously proposed approaches, and has been validated against thickness measured by di erent human operators. We also demonstrate that the use of this method for assigning a distribution of local thickness in FEM crash simulations results in a much more accurate prediction of the real part performance, thus increasing the bene ts of computer simulations in engineering design by enabling zero-prototyping and thus reducing product development costs. The simulation results have been compared to experimental tests, evidencing the advantage of the proposed method. Thus, the proposed approach to consider local thickness distribution in FEM crash simulations has high potential on the product development process of complex and highly demanding injection molded and casted parts and is currently being used by Ford Motor Company.

Estimating Local Part Thickness in Midplane Meshes for Finite Element Analysis

Within the development of motor vehicles, crash safety (e.g. occupant protection, pedestrian protection, low speed damageability), is one of the most important attributes. In order to be able to fulfill the increased requirements in the framework of shorter cycle times and rising pressure to reduce costs, car manufacturers keep intensifying the use of virtual development tools such as those in the domain of Computer Aided Engineering (CAE). For crash simulations, the explicit finite element method (FEM) is applied. The accuracy of the simulation process is highly dependent on the accuracy of the simulation model, including the midplane mesh. One of the roughest approximations typically made is the actual part thickness which, in reality, can vary locally. However, almost always a constant thickness value is defined throughout the entire part due to complexity reasons. On the other hand, for precise fracture analysis within FEM, the correct thickness consideration is one key enabler. Thus, availability of per element thickness information, which does not exist explicitly in the FEM model, can significantly contribute to an improved crash simulation quality, especially regarding fracture prediction. Even though the thickness is not explicitly available from the FEM model, it can be inferred from the original CAD geometric model through geometric calculations. This paper proposes and compares two thickness estimation algorithms based on ray tracing and nearest neighbour 3D range searches. A systematic quantitative analysis of the accuracy of both algorithms is presented, as well as a thorough identification of particular geometric arrangements under which their accuracy can be compared. These results enable the identification of each technique’s weaknesses and hint towards a new, integrated, approach to the problem that linearly combines the estimates produced by each algorithm.

PACOTE ANTI-CORRUPÇÃO DE DILMA?

Olhemos para uma folha de São Paulo no meio do trânsito caótico e dos milhares de arranha-céus, enquanto passam centenas de buzinantes motoqueiros suicidas a uma velocidade estonteante… Depois de milhões de pessoas se terem manifestado no Brasil por causa de megas-processos de corrupção que têm sido descobertos, entre os quais o Petrolão, no qual as investigações apontam que a propina (suborno) foi o triplo do caso Mensalão, eis que a Presidenta Dilma avança para um pacote anti-corrupção. A operação Lava Jato já fala em milhares de milhões de reais. Mas, importante, é que apenas uma medida tem efeitos de aplicação imediata! São 7 as medidas. § Let us look for a Folha de Sao Paulo in the middle of chaotic traffic and thousands of skyscrapers, as they pass hundreds of suicide motorcycle at breakneck speed ... After millions of people have expressed in Brazil because of corruption mega-processes that have been discovered, including the Petrolão in which investigations indicate that the bribe (bribery) was triple the Mensalão case, behold, the President Dilma advances to an anti-corruption package. Operation Lava Jet is already talking about billions of reais. But, importantly, it is that only a measure takes effect immediately applicable! There are 7 steps.