A high performance crashworthiness simulation system based on GPU

Crashworthiness simulation system is one of the key computer-aided engineering (CAE) tools for the automobile industry and implies two potential conflicting requirements: accuracy and efficiency. A parallel crashworthiness simulation system based on graphics processing unit (GPU) architecture and the explicit finite element (FE) method is developed in this work. Implementation details with compute unified device architecture (CUDA) are considered. The entire parallel simulation system involves a parallel hierarchy-territory contact-searching algorithm (HITA) and a parallel penalty contact force calculation algorithm. Three basic GPU-based parallel strategies are suggested to meet the natural parallelism of the explicit FE algorithm. Two free GPU-based numerical calculation libraries, cuBLAS and Thrust, are introduced to decrease the difficulty of programming. Furthermore, a mixed array and a thread map to element strategy are proposed to improve the performance of the test pairs searching. The outer loop of the nested loop through the mixed array is unrolled to realize parallel searching. An efficient storage strategy based on data sorting is presented to realize data transfer between different hierarchies with coalesced access during the contact pairs searching. A thread map to element pattern is implemented to calculate the penetrations and the penetration forces; a double float atomic operation is used to scatter contact forces. The simulation results of the three different models based on the Intel Core i7-930 and the NVIDIA GeForce GTX 580 demonstrate the precision and efficiency of this developed parallel crashworthiness simulation system.     

Crashworthiness design for functionally graded foam-filled bumper beam

Automotive bumper beam is an important component to protect passenger and vehicle from injury and damage induced by severe collapse. Recent studies showed that foam-filled structures have significant advantages in light weight and high energy absorption. In this paper, a novel bumper beam filled with functionally graded foam (FGF) is considered here to explore its crashworthiness. To validate the FGF bumper beam model, the experiments at both component and full vehicle levels are conducted. Parametric study shows that gradient exponential parameter m that controls the variation of foam density has significant effect on bumper beam’s crashworthiness; and the crashworthiness of FGF-filled bumper beam is found much better than that of uniform foam (UF) filled and hollow bumper beam. The multiobjective optimization of FGF-filled bumper beam is also performed by considering specific energy absorption (SEA) and peak impact force as the design objectives, and the wall thickness t, foam densities ρ_f1 and ρ_f2 (foam densities at the end and at mid cross section, respectively) and gradient exponential parameter m as design variables. The Kriging surrogate modeling technique and multiobjective particle swarm optimization (MOPSO) algorithm were implemented to optimize the FGF-filled bumper beam. The optimized FGF-filled bumper beam is of great advantages and it can avoid the harmful local bending behavior and absorb more energy than UF filled and hollow bumper beam. Finally, the optimized FGF-filled bumper beam is installed to a passenger car model, and the results demonstrate that the FGF-filled bumper beam ensures the crashworthiness performance of the passenger car while reduces weight about 14.4% compared with baseline bumper beam.     

Modeling and testing of energy absorbing lightweight materials and structures for automotive applications

As a consequence of the increasing demands in automotive industry concerning crashworthiness and passive safety, the concern for energy management and safety demands also increases. The goal of energy management is to reduce the forces and stresses on an occupant or a pedestrian during a crash event; in some cases it may be possible to reduce the forces by a factor of two. This requires usage of new advanced materials in automotive components. Energy absorbing foams and other lightweight materials like plastics and polymer composites are increasingly used in automotive industry. Hence, extensive study of energy absorbing behavior of these materials as well as the automotive components is needed for further improvements in numerical modeling and crash simulations. The paper enlightens recent advances in investigation of mechanical properties and energy absorption ability of the mentioned lightweight materials as well as modeling with finite element codes for crash simulations.     

Crashworthiness design optimization using successive response surface approximations

 Finite Element (FE) method is among the most powerful tools for crash analysis and simulation. Crashworthiness design of structural members requires repetitive and iterative application of FE simulation. This paper presents a crashworthiness design optimization methodology based on efficient and effective integration of optimization methods, FE simulations, and approximation methods. Optimization methods, although effective in general in solving structural design problems, loose their power in crashworthiness design. Objective and constraint functions in crashworthiness optimization problems are often non-smooth and highly non-linear in terms of design variables and follow from a computationally costly (FE) simulation. In this paper, a sequential approximate optimization method is utilized to deal with both the high computational cost and the non-smooth character. Crashworthiness optimization problem is divided into a series of simpler sub-problems, which are generated using approximations of objective and constraint functions. Approximations are constructed by using statistical model building technique, Response Surface Methodology (RSM) and a Genetic algorithm. The approximate optimization method is applied to solve crashworthiness design problems. These include a cylinder, a simplified vehicle and New Jersey concrete barrier optimization. The results demonstrate that the method is efficient and effective in solving crashworthiness design optimization problems. Received: 30 January 2002 / Accepted: 12 July 2002 Sponsorship for this research by the Federal Highway Administration of US Department of Transportation is gratefully acknowledged. Dr. Nielen Stander at Livermore Software Technology Corporation is also gratefully acknowledged for providing subroutines to create D-optimal experimental designs and the simplified vehicle model.     

On polynomial response surfaces and Kriging for use in structural optimization of crashworthiness

The accuracy of different approximating response surfaces is investigated. In the classical response surface methodology (CRSM) the true response function is usually replaced with a low-order polynomial. In Kriging the true response function is replaced with a low-order polynomial and an error correcting function. In this paper the error part of the approximating response surface is obtained from simple point Kriging theory. The combined polynomial and error correcting function will be addressed as a Kriging surface approximation.To be able to use Kriging the spatial correlation or covariance must be known. In this paper the error is assumed to have a normal distribution and the covariance to depend only on one parameter. The maximum-likelihood method is used to find the latter parameter. A weighted least-square procedure is used to determine the trend before simple point Kriging is used for the error function. In CRSM the surface approximation is determined through an ordinary least-square fit. In both cases the D-optimality criterion has been used to distribute the design points.From this investigation we have found that a low-ordered polynomial assumption should be made with the Kriging approach. We have also concluded that Kriging better than CRSM resolves abrupt changes in the response, e.g. due to buckling, contact or plastic deformation.     

端部方锥形薄壁构件的抗撞性尺寸优化

基于显式有限元技术,采用响应面法,以结构的比吸能为优化函数,以提高车辆吸能原件的抗撞性为目的,研究正方形截面金属薄壁构件的端部锥形尺寸对抗撞性的影响.经过数值分析,得出端部为方锥形的正方形截面薄壁构件的比吸能关于锥形长度和小锥边长的变化规律,这些规律可以用于实际吸能原件的设计,为进一步研究奠定基础.     

Crashworthiness optimization design for foam-filled multi-cell thin-walled structures

Foam-filled thin-walled structure and multi-cell thin-walled structure both have recently gained attentions for their excellent energy absorption capacity. As an integrator of the above two kinds of thin-walled structures, foam-filled multi-cell thin-walled structure (FMTS) may have extremely excellent energy absorption capacity. This paper firstly investigates the energy absorption characteristics of FMTSs by nonlinear finite element analysis through LS-DYNA. Based on the numerical results, it can be found that the FMTS with nine cells has the most excellent crashworthiness characteristics in our considered cases. Thus, the FMTSs with cell number n=9 are then optimized by adopting a multi-objective particle swarm optimization (MOPSO) algorithm to achieve maximum specific energy absorption (SEA) capacity and minimum peak crushing force (PCF). During the process of multi-objective optimization design (MOD), four kinds of commonly used metamodels, namely polynomial response surface (PRS), radial basis function (RBF), Kriging (KRG) and support vector regression (SVR) for SEA and PCF, are established to reduce the computational cost of crash simulations by the finite element method. In order to choose the best metamodel for optimization, the accuracies of these four kinds of metamodels are compared by employing the error evaluation indicators of the relative error (RE) and the root mean square error (RMSE). The optimal design of FMTSs with nine cells is an extremely excellent energy absorber and can be used in the future vehicle body.     

Axial crushing of flattened expanded metal tubes

This paper presents an investigation on the structural behavior of flattened expanded metal tubes subjected to axial crushing. At first, the study is carried out experimentally to investigate the effect of the angle formed between the expanded metal cell and the applied load. Secondly, the results are compared with experimental results for standard expanded metal sheets. Thereafter, numerical analyses are conducted by means of nonlinear finite element models, to investigate the enhancement in the energy absorption characteristics due to flattening of the expanded metal. Both results, experimental and numerical show a significant increase in energy absorbing capacity and mean force for the flattened tubes.     

Effectiveness of the revision to FMVSS 301: FARS and NASS-CDS analysis of fatalities and severe injuries in rear impacts

PurposeThis study investigated the change in the fatality and severe injury risks in rear impacts with vehicle model years (MY) grouped prior to, during the phase-in and after the revision to FMVSS 301.MethodsFARS and NASS-CDS data were used to determine the injury risks of non-ejected occupants in light vehicles involving non-rollover, rear impacts. The data were analyzed by MY groups: 1996–2001, 2002–2007 and 2008+ to represent the years prior to, during the phase-in and post-revision phase-in of FMVSS 301. The 1996–2013 FARS data were analyzed for rear crashes defined by the initial crash direction (IMPACT1) and direction with most damage (IMPACT2) to the rear. Fatality risk was determined by the number of fatally injured occupants per all occupants with known injury status.The 1994–2013 NASS-CDS was analyzed for rear crashes defined by the damage area variable. The risk of severe injury (MAIS 4+F) was determined as the number of occupants with MAIS 4+F injury per all occupants with known injury status. The distribution of rear crashes was determined by impact location and crash severity. NASS-CDS electronic cases with 2008+ MY vehicles were analyzed to evaluate the vehicle and occupant performance.ResultsThe fatality risk was 20.6% in the 1996–2001, 17.3% in the 2002–2007 and 15.0% in the 2008+ MY vehicles using FARS with the initial crash direction variable (IMPACT1) to the rear. There was a 27.1% reduction in risk with post-FMVSS 301 vehicles 2008+ MY. The risk was 19.0%, 15.4% and 12.8% with the most damage variable (IMPACT2) to the rear. There was 32.8% reduction in risk with 2008+ MY vehicles.The NASS-CDS analysis showed that the risk of severe injury (MAIS 4+F) was 0.27 ± 0.05% for 1996–2001, 0.30 ± 0.13% for 2002–2007 and 0.08 ± 0.04% for 2008+ MY year vehicles. There was a 70.2% reduction in the risk for severe injury with 2008+ MY vehicles.The NASS-CDS case review of MAIS 4+F injury in rear impacts of 2008+ MY vehicles that comply with the revised FMVSS 301 indicated that the crashes were very severe and generally involved significant 2nd row intrusion.ConclusionsThe revision to FMVSS 301 has effectively reduced the risks for fatal and severe injury in vehicles compliant with the revision (2008+ MY). The reduction was 27.1–32.8% in fatality risk using FARS data and 70.2% in severe injury risk using the NASS-CDS when compared to vehicles prior to the phase-in of the revised FMVSS 301 (1996–2001 MY vehicles). It is not possible to parse the effects of other design changes in seats and restraint systems that also increased safety over the study years.     

参数化模型数据库在早期碰撞性能预研中的应用及优势

为实现某新车型车身快速验证其碰撞性能以及后续优化其碰撞性能,通过SFE参数化模型数据库搭建了该车型的碰撞车身模型,再结合Isight DOE实验方法进行早期碰撞性能预研。研究结果表明:利用该方法能够很好地满足工程设计要求,且能够大幅缩短车身开发设计周期和降低开发成本。