TEST

Agenda

Agenda

October 22, 2024 07:30 am

Exhibits Open

Exhibition

October 22, 2024 07:30 am

Continental Breakfast

Meals

Walk the exhibition space to grab your quick breakfast before general session.

October 22, 2024 07:30 am

Registration

Registration Desk Open

October 22, 2024 08:30 am

Engineering the Road Ahead with Simulation

General Session

As the Transportation industry evolves and innovates to deliver upon the goals of clean and safe mobility, efficient engineering processes are critical.   A key enabler in shortening and making the engineering processes more efficient is simulation. Visionary automotive companies know how their world-changing ideas will perform well before prototypes and production through the use of simulation and model-based systems engineering.  No longer relegated to CAE departments, simulation has changed tremendously over the past few years, empowering every engineer to innovate faster than ever before. Learn how the latest technologies in AI/ML, physic-based numerics and cloud services have transformed workflows to deliver the latest innovations in electrification, ADAS/AD, SDV, and vehicle attributes.

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Judy Curran
Ansys, Inc.

October 22, 2024 09:05 am

Pushing the Performance Limits: How Ansys powers Oracle Red Bull Racing's Competitive Edge

General Session

The use of numerical tools and virtual analysis plays a critical role in the design and optimization of Formula 1 cars.  To deliver race-winning performance on the track, Oracle Red Bull Racing relies on virtualized design and development to reproduce real-world scenarios and re-create the complex physical environment off the track. This continuous and rapid process ensures the car is optimized for maximum performance at each racetrack. 

Gennaro will highlight how Oracle Red Bull Racing leverages Ansys technologies for aerodynamic development and thermal management to the virtual testing of impact structures. Through the accuracy and fidelity in reproducing virtual testing environments, Ansys enables the Team to reduce costs and time necessary for physical prototypes, enabling quicker iterations and innovations in the fast-paced world of Formula 1. The Innovation Partnership with Ansys is crucial for Oracle Red Bull Racing to maintain the competitive edge in Formula 1 and to deliver exceptional performance on and off the track. 

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Gennaro Serino
Oracle Red Bull Racing

October 22, 2024 09:40 am

Safety Simulation Enhancement Using AI

General Session

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Rajkumar Rajagopalan
STELLANTIS

October 22, 2024 10:05 am

GHBMC and the Applications of GHBMC Models

General Session

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Chin-Hsu Lin
General Motors Research and Development Center

October 22, 2024 10:30 am

Break

Meals

October 22, 2024 10:45 am

Opening Remarks: Electrification and ADAS

Electrification and ADAS

October 22, 2024 10:45 am

Opening Remarks: Electronics and Lighting

Electronics and Lighting

October 22, 2024 10:45 am

Opening Remarks: Safety and Systems

Safety and Systems

October 22, 2024 10:45 am

Opening Remarks: Digital Engineering

Digital Engineering

October 22, 2024 10:45 am

Virtual Validation of Seat Integrity in a Full-Size SUV for Front Crash

Crash I

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Reza Bihamta

October 22, 2024 10:45 am

Simulation Multi-stage draw and ironing for making battery cell by LS-DYNA

Forming I

October 22, 2024 10:45 am

Development of Human Body Model (HBM-C) and Accelerated Positioning Tool (APT-C) for Virtual Testing and Product Development

Occupant and Pedestrian Safety I

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Renuka Jagadish

October 22, 2024 10:45 am

Application of Machine Learning technique to incorporate manufacturing and Testing variation for Robust BIW design for Crash performance

Simulation Methods I

October 22, 2024 11:00 am

AI-Driven Simulation & Design Optimization Framework

Digital Engineering

October 22, 2024 11:00 am

Driving into the Future of Software-Defined Vehicles with Ansys

Electronics and Lighting

The automotive industry is undergoing a transformative shift towards Software-Defined Vehicles (SDVs), where vehicle functionalities are increasingly driven by software. Managing the scalability, flexibility and interoperability of systems across diverse vehicle models is critical for successful deployment. This challenge involves the development of new hardware architectures and electronics as well as new software features. Ansys provides a comprehensive and integrated suite of tools and solutions that address the engineering challenges of software-defined vehicle development. Solutions for model-based system engineering, electronics design from chip to system, software development using real-time plant models and virtual validation of customer features. In this presentation, we will discuss how Ansys solutions enable OEMs and suppliers to partner to design, validate, and deliver the vision of the SDV.

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Domenico Caridi
Ansys

October 22, 2024 11:00 am

Ansys Journey Towards Digital Engineering

Safety and Systems

Digital Engineering is in the focus of many companies to improve their product development. It is concerned with the application of digital methods and tools covering the complete lifecycle of products, from conception through to operation and maintenance. Ansys is going to provide our customers with a digital engineering experience covering important aspects in key areas like MBSE, model-based software development, model-based compliance, and engineering simulation. In the talk our approach to Digital Engineering is discussed with a focus on safe software and compliance to safety and cybersecurity regulations.

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Marc Born
Ansys

October 22, 2024 11:00 am

Develop High-Efficiency Electric Vehicle Powertrains (ConceptEV)

Electrification and ADAS

Ansys ConceptEV is a new innovative cloud-based design and simulation platform for the design of EV powertrains. Engineers can collaborate on a shared system simulation connected to requirements from the start of the design process. ConceptEV provides a model-based approach to optimizing the powertrain system & components with rapid evaluation of different powertrain configurations and component design choices using innovative simulation techniques.

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Pavani Gottipati
Ansys

October 22, 2024 11:10 am

Collapse Load Calibration for Engine Mounts

Crash I

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Bruno Pocksznicki

October 22, 2024 11:10 am

Highly Automated Springback Compensation of the Draw Die

Forming I

October 22, 2024 11:10 am

Preliminary Validation of New Continuum Particle Gas (CPG) Method for Airbag Deployment Simulations

Occupant and Pedestrian Safety I

For airbag deployment simulation, CPM is widely used due to its usability and cost performance. On the other hand, it has some difficulty in representing the gas flow into the narrow space like curtain side airbags. CPG is a new method which solves the Navier-Stokes equation for a space discretized by particles, and is expected to be able to solve his problem by representing pressure propagation and its effect to the fabric more accurately. This paper shows the preliminary validation results comparing test results and CPM for several airbags. CPG shows some better behaviors compared to conventional methods and possibilities to apply to the airbag deployment simulations.

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Hiromichi Ohira
JSOL Corporation

October 22, 2024 11:10 am

Simulating Solder Joint Shapes Post Reflow in Flip Chip Ball Grid Array Packages using ISPG – part 1

Simulation Methods I

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Daniel Vilyatser

October 22, 2024 11:30 am

Battery Modeling and Manufacturing Simulation - What's New

Electrification and ADAS

One of the biggest impediments to widespread adoption of electric transportation is battery cost. Performance, safety, and hitting time-to-market all remain challenges for the EV design cycle along with an evolving technological, supply chain and regulatory landscape for batteries. Tight product cycles make it impossible to use the build, test, fix approach against a multitude of battery design choices that exist at the material and component level. Simulation is therefore critical in EV and battery product development. Cell chemistry/format, manufacturing quality, cooling system and mechanical design significantly impact vehicle level attributes such as safety and performance with some tradeoffs involved. All of the components then need to be integrated and system performance validated against real-life usage conditions. On the safety side with new mandates that require passenger warnings around thermal runaway, propagation resistance becomes important whether thermally triggered or mechanically triggered. This presentation will cover an overview of Ansys battery solutions including key challenges in battery manufacturing, safety and how system level performance and what if failure scenarios can be investigated.

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Vidyu Challa, PhD
Ansys

October 22, 2024 11:30 am

New Electronics Design Capabilities

Electronics and Lighting

Automotive printed circuit boards (PCBs) are the heart of all modern vehicles as they play a critical role in all advanced electronic features including autonomous driving systems, safety, infotainment, and connectivity solutions. In this presentation we will be covering the latest advancements in electronics, thermal and mechanical simulations of PCBs using Ansys tools. The presentation will highlight newer technologies to create and solve complex PCB assemblies including connectors, flex cables and housing to investigate the performance of the complete sub system and not the components in isolation, which is critical for automotive applications. Full vehicle simulations will also be presented showing virtual electromagnetic compatibility (EMC) of PCBs installed inside the vehicle along with the electrical/electronics architecture.

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Juliano Mologni
Ansys

October 22, 2024 11:30 am

Safety Considerations for AI in Automotive Applications

Safety and Systems

An overview of the new ISO Standard: ISO/PAS 8800 (Road vehicles Safety and artificial intelligence). This standards defines safety-related properties and risk factors impacting the insufficient performance and malfunctioning behavior of Artificial Intelligence (AI) within a road vehicle context. Emphasis on the key elements of this standard such as deviation of safety requirements, data quality and completeness, SW architecture measures for the control and mitigation of failures and the evidence required to support an assurance argument for the overall safety of an automotive system that employes AI. Real life challenges to the implementation of this standard will be also covered for selected design areas. Activities I am involved in at both Aptiv and ISO/SAE/SCC to address these challenges are also highlighted.

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Majed Mohammed
Aptiv

October 22, 2024 11:30 am

Accelerating Design Exploration (Discovery)

Digital Engineering

Capturing design insights earlier in the design process in a critical driver to shift-left initiatives, enabling increased innovation, reduced cycles times, and improved quality through earlier issue detection. Attend this session to learn how Ansys Discovery is leveraging native GPU computing and a next-generation integrated user experience to break down the barrier to upfront simulation across multiple automotive application areas, providing instantaneous design guidance where and when you need it most. Stop waiting for results and start acting on them.

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Justin Hendrickson
Ansys

October 22, 2024 11:35 am

Virtual validation of HIT: identification of key parameters to achieve ECE-R21/FMVSS201 requirements

Crash I

October 22, 2024 11:35 am

Hot Forming Simulation with Ansys Forming and LS-DYNA

Forming I

October 22, 2024 11:35 am

Utilizing a validated laminated glass model to simulate pedestrian head impact on a windshield

Occupant and Pedestrian Safety I

October 22, 2024 11:35 am

Simulating Solder Joint Shapes Post Reflow in Flip Chip Ball Grid Array Packages using ISPG – part 2

Simulation Methods I

Accurate simulation of solder joint shapes and dimensions during the Flip Chip Ball Grid Array (FCBGA) packaging reflow process is crucial for ensuring signal integrity and structural reliability in electronic devices. This presentation introduces a novel approach utilizing the adaptive Incompressible Smooth Particle Galerkin (ISPG) method in LS-DYNA.   Our methodology involves calibrating the ISPG model using NVIDIA's FCBGA, where a set of optimal parameters was identified. To validate the calibrated model, various FCBGA designs were simulated and compared against experimental solder joint cross-sectional data. The results demonstrated a strong correlation between the calibrated model and the experimental data, confirming the high accuracy of the ISPG method.  This study highlights the significant impact of ISPG material model parameters on solder joint morphology, aiming to improve the design process by identifying key parameters.

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Yogev Buzaglo
NVIDIA

October 22, 2024 12:00 pm

Lunch

Meals

October 22, 2024 12:00 pm

Sponsored Lunch - HPE | AMD

Buffet lunch will be served during:

Advancements in Sustainable HPC Solutions for Ansys Applications

At this lunch presentation AMD and HPE will address the complex simulation challenges faced by our enterprise CAE customers. This session will focus on the deployment of highly efficient high-performance computing (HPC) clusters, power management options, advanced storage systems, and robust data management solutions. With customers relying on advanced modeling and simulation as a key business function, it’s important to choose HPC systems that optimize performance for a wide range of applications. Additionally, as thermal and power management become increasingly critical in next-generation HPC systems, customers need to understand the advantages of liquid cooling technology.

Join us to also hear about the latest performance results of AMD EPYC™ processors running Ansys CFX, Ansys Fluent, Ansys Mechanical, and Ansys LS-DYNA, demonstrating their capabilities in real-world applications.

October 22, 2024 12:00 pm

Sponsored Lunch - TotalCAE

Buffet lunch will be served during:

Case Studies in Utilizing High Performance Computing (HPC) and AI/ML for Digital Transformation

High-performance computing (HPC) and AI/ML accelerate solving complex simulations at unprecedented speeds to innovate faster.  This talk will focus on case studies of clients utilizing TotalCAE-managed HPC services for clusters and cloud to accelerate their digital transformation using HPC, cloud, and AI/ML for their CAE workflows.

October 22, 2024 12:00 pm

General Lunch

October 22, 2024 01:15 pm

A Refined Approach in Sherlock Simulation to Assess Reliability of New Electronic Design and Assist Root Cause Failure Analysis

Electronics and Lighting

A refined approach will be discussed to accurately assess reliability of new electronic design, as well as to assist the root cause identification of validation test failures with confidence. This approach will measure important parameters of more vulnerable devices in new electronic design proactively, or to be reactive to validation test failures. A few real-world examples will be given to demonstrate this approach.

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Yong Hong
Harman International

October 22, 2024 01:15 pm

Process Integration and Design Optimization (optiSLang)

Digital Engineering

Simulation has become an indispensable component of the modern product development cycle, enabling faster and more efficient design iterations. A critical aspect of this process is the digitalization and optimization of simulation workflows through the seamless integration of multidisciplinary computer-aided engineering (CAE) tools. In this presentation, we will demonstrate how to maximize the potential of your existing CAE tools by orchestrating and optimizing these workflows with Ansys optiSLang, the cutting-edge process integration and design optimization (PIDO) solution. By leveraging optiSLang, engineers can streamline complex simulations, reduce manual effort, and accelerate time-to-market. This talk will delve into key methodologies, including Sensitivity Analysis, Design Exploration, Optimization, and Robustness and Reliability assessments, showing how these approaches can improve product quality while mitigating risk and uncertainty in real-world applications.

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Ravi Teja Katragadda
Ansys

October 22, 2024 01:15 pm

Battery Thermal Runaway Mitigation

Electrification and ADAS

In this presentation, we will focus on EV battery thermal runaway propagation simulation. In such a simulation, we model the heat generation due to exothermal reactions during thermal runaway and the subsequent heat transfer of the heat to the cooling system. The exothermal reaction models are calibrated from the accelerating rate calorimetry (ARC) data of a battery cell. The heat transfer is modelled using conjugate heat transfer models in computational fluid dynamics (CFD). Modelling of venting and vented gas reaction is also discussed. Several validated examples will be shown in this presentation including module/pack runaway propagation and the associated venting and vented gas reaction.

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Xiao Hu
Ansys

October 22, 2024 01:15 pm

Using Medini Analyze for Functional Safety

Safety and Systems

How doing our FMEDAs in Medini instead of Excel: - Improved the quality of our analysis - Resulting in a higher confidence in our design. - Made extracting data on specific failures quicker, easier and more accurate - Made estimating the risk of missing/inoperative Safety Mechanism easier and more accurate Traceability matrix between SFMEA and FMEDA improved confidence in our design.

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Neil van Zyl
BorgWarner

October 22, 2024 01:15 pm

Computational modeling of tensile split Hopkinson bar tests on carbon-carbon composites using continuum and mesoscale approaches

Aerospace Structure Impact and Dynamics I 

The high strength, toughness, quasi-ductility over monolithic ceramics, and elevated temperature oxidation resistance make carbon-carbon (C/C) ceramic matrix composites (CMCs) excellent candidates for hypersonic vehicle components expected to experience high strain rates and high temperatures in service. However, accurate characterization of the material behavior under such extreme/harsh conditions presents significant challenges. This work will present the results of LS-DYNA computations conducted in support of an ongoing Southwest Research Institute (SwRI) internal research (IR) program focused on the high temperature, high strain rate behavior of C/C composites. The goal of this IR program is to develop and fabricate a system capable of rapidly heating metals and C/C CMC test specimens up to 4000°F to facilitate elevated temperature tensile split-Hopkinson pressure bar (SHPB) testing. This talk will provide an overview of SwRI’s dynamic material testing capabilities, challenges associated with the current effort, and will primarily focus the use of explicit finite element (FE) simulations to support the experimental program. Results of a computational investigation into apparent non-equilibrium behavior exhibited in previous SHPB tension tests conducted on a commercially available C/C composite material will be presented. Said non-equilibrium behavior is suggested by the measured signals on the input and output bars during these tests, particularly the dissimilarity of the transmitted wave and the sum of the incident and reflected waves. In the computations, the entire SHPB set up is represented/meshed. Two different approaches are taken to model the SHPB tension test coupons. The first approach considers the woven C/C CMC as a smeared homogeneous continuum. These continuum simulations resulted in sudden, brittle failure, which leads to wave attenuation/dispersion of the transmitted strain signals (i.e., the transmitter bar strain signals decrease in amplitude with increasing propagation distance). To correlate the simulated and experimental strain amplitude at the location of the transmitter bar strain gage in the tests, it was found that the value of the maximum principal stress at failure in the continuum models needed to be increased to what the authors believe is an unrealistically large value. It was also found that the continuum modeling approach is unable to capture the widening of the transmitter bar signals that is present in the SPHB experimental data. In the second modeling approach, the woven C/C CMC mesostructure (i.e., the tows and matrix) was explicitly modeled. Compared to the continuum simulations, the mesoscale simulations exhibited a more progressive failure, which was found to result in enough additional “ductility” such that the amplitude of the strain and force signals did not decrease with increasing propagation distance along the transmitter bar. Additionally, the mesoscale simulations resulted in transmitted strain signals that were wider those in the continuum simulations and were in good agreement to those in the experiments. Whereas the maximum principal stress at failure used in the continuum models had to be unrealistically increased to correlate the simulated transmitted strain signals to those in the experiment, this was not the case for the failure properties used for the tows and matrix in the mesoscale simulations, highlighting the importance of the mesoscale approach.

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Christopher Sorini
Southwest Research Institute (SwRI)

October 22, 2024 01:15 pm

Emergency Brace Positioning and Injury Risk Prediction of Aircraft Occupants under Impact Loading

Human Body Models

THUMS (Total Human Model for Safety) is a detailed biofidelic finite element model of the human body, which encompass different genders and physiques including detailed anatomical features of the skeletal structure, internal organs, and other soft tissues like skin, flesh, and ligaments. The application of THUMS in numerical simulation offers exciting opportunities in automotive and civil aerospace development in areas such as safety, comfort, and ergonomics. These models will play an increasingly important role in the study of human body kinematics and assessment of injury risks in collision accidents.   The Civil Aviation University of China (CAUC) aims to establish a posture database according to civil aviation standards and perform detailed numerical studies on the biomechanical response of aircraft occupants using THUMS in a variety of simulated impact scenarios. CAUC collaborated with Arup and its software house Oasys LS-DYNA, to help build this posture database and explore the feasibility of using Oasys PRIMER (a world leading LS-DYNA pre-processor) with its comprehensive human body model positioning tools and THUMS positioning metadata to achieve complex emergency braced postures.  This presentation describes the entire positioning workflow used to achieve complex brace postures using the multi-stage positioning method in Oasys PRIMER and the *CONTROL_STAGED_CONSTRUCTION keyword in LS-DYNA. Further investigations were made to optimize simulation run times. Using a generic aircraft seat, a series of standard dynamic load cases are performed to predict occupant kinematics and the extent of injury risk to the aircraft occupant. This research will contribute to the wider application of THUMS in the aviation industry and promote biomechanical research into aircraft occupant safety.

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Emily Owen
Oasys LS-DYNA Environment

October 22, 2024 01:15 pm

Sonic weld characterization and FEA modeling method development for automotive applications

Material and Constitutive Modelling I

Joining is a critical part of any structure for transferring load and maintaining integrity for the product. Ultrasonic weld is one of the popular methods for joining plastic parts in automotive industry. Along with providing a visually demanding finish, the method has been established for tight, strong, and dimensionally accurate joints. With the increase of complexity and integration of electrical and sensing instrumentation in autonomous and electric vehicles, ultrasonic weld provides a necessary means of attaching parts into plastic parts without compromising visual impact. However, the sonic weld performance is yet to be quantified, and the criteria for capturing weld separation, and losing this connected load path during structural vehicle analysis, has not been studied extensively.  Sonic welds, even though it is a very effective joining method, the whole welding tooling process is expensive and time consuming. Ideally, to optimize the welding spot number and develop future cost-effective welding method, it is crucial to understand the actual weld performance under various variables such as material, thickness, temperature, strain rates etc.  In the following study, sonic weld performance has been evaluated in five different material combinations, three different strain rates and three different temperatures. Based on the analysis, a fully characterized FEA sonic weld modeling method has been developed, which captures weld separation, for in-production parts joined with sonic welding method. This method can be applied on full vehicle level analysis, like front and rear low speed, and enables for optimized design by determining an ideal number of sonic welds necessary for this type of structural loading.

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ABM Iftekharul Islam
General Motors

October 22, 2024 01:15 pm

An Application of Shape Similarity Recognition Using PCA based Dimensional Compression

SDM

In recent years, the speed required for product development has increased significantly. With the increasing sophistication of requirement levels, data-driven development utilizing past data is gaining attention in the automotive industry. Compared to physical testing, simulation is characterized by the ease of obtaining information through calculation and analysis, but on the other hand, handling huge amounts of data is a challenge. In this paper, we propose a new process to search for similar behavior of the part of interest from dozens of crash simulation results by using the order-reduction technique. Assuming that an irregularity occurred in the behavior of a member, the modeling history database was searched for members with similar irregularities using the shape of the member as a key, and highly similar behaviors were found in the database.

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MASAHIRO OKAMURA
JSOL Corporation

October 22, 2024 01:40 pm

Adaptive FEM-SPH Numerical Models of CFRP Composite Materials under Hypervelocity Impacts

Aerospace Structure Impact & Dynamics I

Impacts at or exceeding speeds of 7 km/s are classified as hypervelocity impacts (HVI). Micro-meteorites and space debris travelling at these speeds pose a present and prevalent threat to the operational safety of satellites. The damage can be measured through loss of operation and the corresponding economic expenses. HVIs against satellite shielding structures need to be understood to improve their design, however, physical testing is usually associated with high economic expenses. A commonly accepted and widely used alternative relies on numerical modelling of HVI shielding structures. More recently, the use of advanced composite materials in space applications, such as carbon fiber reinforced polymers (CFRPs), has increased. This necessitates the development of accurate numerical modelling techniques adept at predicting failure mechanisms and damage under these extreme loading conditions. Generally, numerical techniques employed in HVI modelling rely on the Lagrangian implementation of the finite element method (FEM; well-suited for tracking relative motion between interfaces, useful in modelling delamination) or the meshfree smoothed particles hydrodynamics method (SPH; excellent for replicating extreme deformation and fragmentation). To leverage the benefits of both methods and capture the wide range of failure mechanisms and damage occurring simultaneously, this study employs an adaptive FEM-SPH method. 16-ply laminated composites under HVI by three different types of orbital debris (steel, aluminum and nylon, classified as high, medium and low-density materials by NASA, respectively) are studied. Crater size and delaminated area are used as comparison metrics to gauge the accuracy of the numerical models and variations in the prediction of these features are explored and quantified across different composite material models.

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Anthony Gudisey

October 22, 2024 01:40 pm

Introducing HBMs in Safety Simulations. Biofidelic positioning, and post-processing with ANSA and META

Human Body Models

HBMs have become a much-needed tool for the safety simulations of the automotive industry. Out-of-position load cases for passengers and simulations for other vulnerable road users, like pedestrians and cyclists are increasingly needed, and HBMs can address this need. Euro NCAP in its Vision 2030 plans to replace ATDs with HBMs and the same is expected by other consumer information programs.  Nevertheless positioning, pre-processing and post-processing of these models on a level suitable for industrial use has not been straight-forward until now.  ANSA, offers a novel solution to this complex problem, making the positioning and handling of an HBM, as easy as with an ATD model. Using an advanced integrated MBD solver in parallel with morphing algorithms, engineers are provided with real time articulation and positioning of a HBM within an easy user interface. While the user just articulates the human model with the mouse in a most direct way, the biofidelic joint modelling guarantees realistic model movements and the generation of a ready-to-run model without the need of pre-simulation.  In parallel we are developing tools to tackle the problem of producing variants of an HBM adapting it to different anthropometries, thus better representing the population variability. We are addressing the problem with morphing and remeshing tools along with methods of incorporating anthropometric data into our algorithms.  Vulnerable road users is another area of great interest where HBMs are the only choice. We are conducting our own research projects related to cyclists' postures. Through statistical processing of laboratory scanned data we aim to produce statistical rider models that will be applied on the HBMs. This gives the possibility to the engineers, to simulate crash events of any kind of bicycle for any rider anthropometry.  On the post-processing side, running interactively or in batch mode, the META HBM tool automatically creates PPTX and PDF reports including videos and images of GHBM's kinematics, strain contour plots, elements erosion identification, chest-bands deformations, and injury criteria calculations (Brain CSDM, Abdominal soft tissue organs SED, etc.). Moreover, time history results can be extracted from the Occupant Injury Criteria tool. Injury criteria like HIC, BrIC, Nij, etc. are calculated. The extracted and calculated results can be compared to corresponding results of Anthropomorphic Test Devices (ATDs), while it is also easy to make comparisons between multiple HBMs simulation runs or between results from different solvers.

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Lambros Rorris
BETA CAE SYSTEMS INTERNATIONAL AG

October 22, 2024 01:40 pm

From Test to Calibrated Material Card using AIaugmented Workflows - A Case Study with Industrial Material for Aerospace and Automotive Applications

Material and Constitutive Modeling I

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Suri Bala

October 22, 2024 01:40 pm

Facilitating Virtual Testing at an Industrial Level by Simulation Data Management

SDM

From an industrial or productive standpoint, the scale of simulation   models, the number of involved simulation model components, and the complexity of the utilized processes with a vast amount of data are at a level that is challenging to manage manually. The introduction of virtual testing adds to the complexity of the development process and the quantity of data to be handled. Consequently, the use of an SDM system for this purpose can be advantageous in numerous ways.  The introduction of virtual testing can be accomplished in several steps. The initial step is the automation of data preparation, encompassing both input data and produced result data for both the OEM and the testing authority. Subsequent steps involve the implementation of individual processes and security mechanisms against data manipulation. This paper/presentation primarily addresses the initial step and outlines a methodology for achieving the objective of safeguarding against data manipulation and intellectual property (IP) infringem

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Marko Thiele
SCALE GmbH

October 22, 2024 01:45 pm

Electric Motor Design and Development - What's New

Electrification and ADAS

Ansys Electronics continues to demonstrate its multi-decade leadership in computational electromagnetics and multi physics simulations.

In the newest release 2024R2, the unmatched market leading and multiphysics motor design simulation software, Ansys Motor-CAD, now offers capabilities that are further widening the competitive gap. Some of these new capabilities are: three new cooling methods; extending the capability of the adaptive templates; and enhanced electromagnetics.

As an advanced electromagnetic field solver that widely used for electric machine design and analysis, Ansys Maxwell in 2024R2 now has: an improved formulation for the sliding mesh interface called Continuum Air; a new reduced order model(ROM) for brush commutating machines; and a new User Defined Primitive (UDP) for hairpin coil.

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Yijang Jia
Ansys

October 22, 2024 01:45 pm

Session Title TBD - AI Topic

Digital Engineering

October 22, 2024 01:45 pm

EMI/EMC Simulation - Latest Capabilities from Chips to Full Vehicle

Electronics and Lighting

The design complexity of high-performance electronics systems, including chip-package-board and accompanying enclosures and housings and even entire systems such as electric vehicles (EV) has dramatically increased in recent years. With further requirements to integrate high-speed digital functionality for infotainment and safety systems such as HDMI, USB, DDR4, PCIe and UCIe, reaching compliance with EMI/EMC (ElectroMagnetic Interferences and Compatibility) standards has become ever more challenging. In addition, electromagnetic co-existence issues with RF wireless protocols such as AM/FM, Satellite Radio, WiFi, Bluetooth, ZigBee, and 5G/6G can potentially occur, causing signal integrity issues within and across systems resulting in bandwidth reduction and reduced performance. Finally, the push to EV technology with the demands for higher voltages and operating frequencies has introduced some of the most challenging problems in EV development. In the worst cases, addressing EMI/EMC issues requires a significant re-design of critical EV systems resulting in increased cost of design and delayed time to market. This presentation reviews the most recent advancements in electromagnetic simulation methodologies for virtual EMI/EMC testing covering the entire design spectrum from chips to systems on to full EV capacity.

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Matthew Commens
Ansys

October 22, 2024 01:45 pm

A Holistic Approach to Prevent Unexpected Behavior in Autonomous Vehicles

Safety and Systems

Modern vehicles are getting more and more complex and an approach that utilizes industry best practices is needed to prevent the vehicle from behaving in ways that are unwanted and/or dangerous. This presentation describes an approach based on a process model, automotive functional safety and Safety of the Intended Function as well as automotive cyber security to prevent unexpected behavior. We will investigate how the process can be used to ensure that requirements are documented, understood and implemented. Then we will use ISO 26262:2018 to explain how unreasonable risk due to E/E malfunctions can be prevented. After that we will discuss the use of ISO 21448 (SOTIF) to prevent malfunctions caused by technological insufficiency and foreseeable misuse. The final layer of protection is achieved by using ISO 21434 cyber security to identify and analyze hacking attack risks.

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Heinz Bodo Seifert
TUV Rheinland Group

October 22, 2024 02:05 pm

Bird Strike Resistance of Thermoplastic Composite Panels: Experimental and Numerical Analysis

Aerospace Structure Impact and Dynamics I 

October 22, 2024 02:05 pm

HANS meets the GNS software Working with HBMs in Generator4 and Animator4

Human Body Models

Current trends and developments in the automotive market have caused changes in the way we evaluate and analyze our vehicles. Reacting to a growing demand for realism in simulations, Hans was born. Hans is the DYNAmore's human model, characterized by its detail and excellent performance. Realistic Human Body Models (HBMs) are one of the major revolutions in the world of vehicle development simulation nowadays. But the greater realism of the models comes together with a greater complexity in their handling. GNS offers its well-known products in response to this new need: Generator4 and Animator4 . Thanks to Generator4, Hans and other HBMs can sit comfortably through a simple GUI that is as flexible as the model itself. An industry that requires high realism in passenger models also expects a high level of accuracy in capturing the effects of changing model position and interaction with its environment, reflecting seat deformations and realistic positioning of anchoring systems.

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leyre Benito Cia
GNS mbH

October 22, 2024 02:05 pm

Polymer Calibration using Generative AI-powered Workflows

Material and Constitutive Modeling I

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Suri Bala

October 22, 2024 02:05 pm

Template-driven management of model and loadcase variants for LS-DYNA simulations

SDM

In recent years, crash and safety simulations have reached a very high level of accuracy in the prediction of the crashworthiness of the vehicle and the probability of injury for occupants and pedestrians under a multitude of loading scenarios. Among several factors, this achievement is also attributed to the fine resolution of finite element models that enables the precise representation of even the smallest parts and geometric features affecting the simulation results and the increase in the number of simulated loadcases. However, accuracy does come with a cost: Model size and variability have considerably increased, together with the number of loading scenarios that need to be simulated on each model variant.  From the definition of the different model variants from the CAD structure and the subdivision of the simulation models into functional sub-assemblies, to the set-up of the numerous different types and flavors of loadcases, there's one thing in common: The modular management of the model at each phase of its lifecycle. At early phases, modules are as small as CAD parts. Later, modules become functional sub-assemblies which, for crash and safety loadcases, are handled as include files. Although the modular way of work is the only reliable method to enable parallel work on different areas of the model, it increases the“administration cost” during the simulation preparation, as the pool of different modules (be they parts or include files) needs to be consumed by higher level structures in a way that facilitates data reuse and enables traceability throughout the complete digital thread of a simulation model.  BETA CAE Systems' Suite of applications addresses these challenges during model build and loadcase set-up with its Modular Model and Run Management solutions, that facilitate the handling of the different model and loadcase variants in a way that maximizes data reuse and enables traceability from part to simulation run, while mitigating the “administration cost” with the extensive use of templates. From the population of CAE subsystems based on the CAD structure, to the definition of different subsystem variants, vehicle configurations and loadcases, templates act as recipes that hold the instructions on which ingredients to use and how, in order to complete each given task.  This work discusses the definition and use of templates during model build and loadcase set-up, focusing on three key phases of the simulation preparation: First, the CAD to CAE structure mapping during Subsystem definition from PDM/PLM structures. Second, the handling of Subsystem variants in the scope of the different vehicle configurations. Third, the handling of parametric include files for the definition of Loadcases. Insights are given on the methods used for the adaptation of the templates to the specifications of each model in hand and how these are finally interpreted into LS-DYNA keywords behind the scenes, by making use of parameters, transformations and ID management techniques.

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Irene Makropoulou
BETA CAE Systems

October 22, 2024 02:15 pm

High Frequency Modeling of HV Bus Electric Power Conversion System

Electronics and Lighting

Developing a High Frequency (up to 10 MHz) Model of HV bus electric power conversion system in order to minimize conducted EMC, CM noise & leakage current through out the system and optimize CM filter design and cable shielding strategy.

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Arash Bavili
General Motors

October 22, 2024 02:15 pm

Honda Material Intelligent Database for Highly Efficient and Environmentally Friendly R&D

Digital Engineering

Honda has been constructing a unique material intelligence digital platform using material database Granta for the purpose of highly efficient, environmentally friendly R&D. We’ve designed a material database structure ’schema’ , which is easy to be utilized for fields of design, simulation (functional and manufacturing CAE, additive manufacturing, materials informatics), additive, procurement, and material development.  Over thousand users in the company accesses to the in-house material database and we’re now tackling to enlarge its application for Honda products not only automotive, but motorcycle, power products, aerospace, and other technical fields. Besides, under VUCA circumstance for future, we suggest a prospective digital utilization on material information toward environmental, regulatory issues, and AI technology progress.

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Toru Furusawa
Honda R&D Co., Ltd

October 22, 2024 02:15 pm

Why MBSE? MBSE at the Intersection of Safety and Systems Engineering in the Automotive Domain

Safety and Systems

Legacy approaches to automotive system design often consider systems engineering and systems safety analysis as critical yet separate engineering activities. This results in specialized but siloed and disconnected processes, ill-equipped to efficiently respond to industry trends of increasing product complexity and reduced development times. To counter these challenges, as in other industries, automotive systems engineering has adopted a Digital Engineering approach centered around a model-based representation of the design intent. However, unlike other industries, model-based work products in automotive are not a direct deliverable to our customers. Why then do we invest significant engineering resources into model-based systems engineering (MBSE)? This presentation will highlight the value proposition of closely coupling automotive systems engineering and safety workstreams via a shared, common SysML model. Discussion will include how the model enables an integrated development process where safety is designed into the system from day one. Additional return on modeling investment will be shown in the form of integrated system simulations, efficiencies in system verification and validation, and accelerated design certification and instantiation.

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Jeremy Ross
Ford

October 22, 2024 02:15 pm

Electric Powertrain Durability and NVH Prediction

Electrification and ADAS

The electric powertrain has become a pivotal component in modern electric vehicles (EVs), directly impacting their performance, efficiency, and user experience. Ensuring the durability and reliability of the electric powertrain is crucial for the long-term success of EVs. This study focuses on developing predictive models for the durability of electric powertrains, with particular attention to Noise, Vibration, and Harshness (NVH) characteristics, which are critical to both the perceived quality and mechanical integrity of the system. By integrating advanced simulation techniques, material fatigue analysis, and real-world testing data, the research aims to enhance the accuracy of durability predictions and optimize NVH performance. The findings provide insights into the key factors affecting powertrain longevity and noise reduction, offering valuable guidance for the design and engineering of more robust and quieter electric vehicles.

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Santosh Kottalgi
Ansys

October 22, 2024 02:30 pm

Preload of Rotorcraft Blade for Impact Simulation

Aerospace Structure Impact and Dynamics I 

October 22, 2024 02:30 pm

Hans - Human Body Model: EnHansments

Human Body Models

October 22, 2024 02:30 pm

Recent advancements in material models

Material and Constitutive Modelling I

This contribution will deal with the latest developments in the field of material models in LS-DYNA. This includes completely new methods as well as extensions and improvements to existing models. The range of materials concerned includes metals, foams, composites, plastics, honeycombs, glass, adhesives, damage and failure models, and others. The new developments are aimed at improving prediction quality, robustness, performance, and user-friendliness. Examples will be used to illustrate the new features.

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Tobias Erhart
Dynamore, an Ansys Company

October 22, 2024 02:30 pm

Manage multi-disciplinary load cases in SDM: model setup and evaluation of results

SDM

Due to the continuously increasing demand in Computer Aided Engineering (CAE), it is essential for high efficiency and transparency to automate and standardize processes. In many cases, Simulation Data Management (SDM) software is used for this purpose.   To achieve all mechanical target values of a product, there are several standard disciplines in the field of CAE, such as crash, Noise Vibration Harshness (NVH) or fatigue. Assembly, solving and postprocessing for these disciplines can differ greatly from one another. For this reason, it is best practice in many companies to carry out the optimization of a model in each discipline separately and to compare the results and structural adjustments with other disciplines at regular intervals. This approach can lead to two disadvantages:   Firstly, this results in redundant work. Model adjustments successful for one discipline must be redone in other disciplines later on. Secondly, deterioration in other disciplines may be discovered late: Model modifications that produce positive results for one discipline can have a negative impact on the results in other disciplines. This can lead to short-term changes of plans, postponements, or additional costs for optimizations.   With the help of a base model and SDM, several disciplines can be covered based on a single source of truth. The basic approach is not to work directly on the solver specific files, but on the base model itself. All discipline and solver specific files are generated from this file via SDM automatically. As an example, the two disciplines crash and NVH are considered in this paper. LS-Dyna is used as solver for both disciplines.   There are several criteria that must be met to successfully carry out multidisciplinary variant creation and result evaluation:   A complete database for all discipline-specific information, such as load case definitions or connection configuration is essential. Furthermore, a flexible and simple selection of the load cases is needed. It is also crucial to have an automatic process flow from the creation of the include to the finished report. This report must be designed according to the discipline-specific load case. A clear overview of all created variants is as important as a dynamic variant comparison of the results for each discipline.   The SDM software SCALE.sdm fulfills all these points, which is why it is used as the basis for this paper. So far SCALE.sdm is used by users in the industry like in the best practice example mentioned above: For each discipline there is a separate variant tree that is considered independently. By customizing specific key features such as an automatic creation of the include- and inter-include-connections, it is now possible to display all disciplines together with a single variant tree.   This approach makes it possible to avoid the above-mentioned disadvantages of the separate discipline approach: All the desired disciplines can now be covered by a single model modification, allowing the user to work effectively on structural optimizations while minimizing resources.

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Andreas Lohbrunner
SCALEsdm. US. Corp.

October 22, 2024 02:45 pm

Lighting & Optical Simulation Overview and Technology Update

Electronics and Lighting

Lighting technology is significantly evolving. Displays are becoming larger, brighter, and multi-dimensional. Lighting systems are more customizable, flexible, adaptable and complex as ever. Imaging sensors are getting smaller, while image quality is getting higher. For many of these optical systems, challenges are being solved at the micro-level, but system-level integration and performance are equally as complex. With the Optics portfolio at Ansys, we can bridge the gap between microstructure optimization and system level performance. Many advances in our Optics products have enabled us to keep up with the evolving lighting & sensing technologies, such as improved GPU acceleration, stray light analysis, and full optical product workflows. Join to discover the Ansys Optics solution and its recent innovations.

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Mike Grove
Ansys

October 22, 2024 02:45 pm

Power Electronics Simulation

Electrification and ADAS

Modern vehicles put new demands on electronic devices and systems for the control and conversion of electrical power. Electrification promises more efficient powertrains with increased range, faster charging, and lower weight but they also introduce new sources of electromagnetic interference (EMI). The design and optimization of these systems are essential to achieving greater power density, efficiency, and reliability. This presentation will introduce the extensive simulation capabilities used to design and fine-tune power electronics, predict their behavior under both normal and faulty conditions, and proactively address potential issues – from analysis and sizing of power converter topologies to reduced-order modeling of electromagnetic components and electronics reliability.

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Peng Han
Ansys

October 22, 2024 02:45 pm

Autonomy Use Case for Safety Analysis of Complex Models

Safety and Systems

The complexity of an open pit mining Fleet Management System (FMS) presents challenges for Medini Analyze FFMEA tools. The FMS is structured into four main architectural layersSite Operations, FMS, Autonomy, and Drive-By-Wire each containing multiple internal layers and many functions. The AIAG-VDA 2019 FMEA Handbook reflected in Medini does not directly provide a concept of system nesting or module reuse found in the design. This session explores an example of an open pit FMS and an approach using Medini to address its complexity. The approach is a work in progress, building on lessons from previous efforts and enhanced through collaboration with the Medini Analyze Expert Team.

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Andy Saxsma
Hexagon AB

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Varun Jayaram
Hexagon

October 22, 2024 02:45 pm

Update on Ansys Solutions for Aerodynamics and Thermal (Fluent)

Digital Engineering

Automotive external aerodynamics is a key factor in vehicle design, impacting aspects such as performance, fuel efficiency, stability, noise, and comfort. In electric vehicles (EVs), aerodynamic performance is especially critical as it significantly affects battery range and longevity. Moreover, EVs generate significantly less engine noise compared to traditional combustion engines, making aerodynamic designs crucial for achieving acoustic comfort. Another crucial area for the automotive industry is thermal management. Efficient thermal management systems help maintain the right temperature for the engine, battery, and other critical parts, ensuring optimal performance and longevity of vehicle components. This presentation will showcase the latest Ansys solutions in the field of aerodynamics and thermal management. We will also demonstrate how our Native Multi-GPU solver can accelerate simulations by an order of magnitude, enhancing the accuracy of aerodynamic predictions and enabling faster design iterations and better optimization. Lastly, we are thrilled to introduce our latest AI innovation, Ansys SimAI, which promises to revolutionize data-driven design.

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Marco Coderoni
Ansys

October 22, 2024 02:55 pm

Break

October 22, 2024 03:10 pm

Advancing Battery Safety Through Multi-Physics Modeling: From Experimental Data to Validated Simulation Models

Battery/Electric Vehicle

The rapid advancement of battery technology has driven the demand for advanced tools for a comprehensive understanding of battery cell behavior. This contribution proposes a holistic approach to generate digital twins of battery cells via coupled electro-thermo-mechanical modeling techniques within LS-DYNA. These models serve as precise representations of real-world battery cells, contributing to the development of efficient and secure battery systems.

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Martin Schwab
4a engineering GmbH

October 22, 2024 03:10 pm

Topology Optimization for Giga-Casting Design in Automotive Bodies Using LS-TASC & LS-DYNA

Machine Learning

October 22, 2024 03:10 pm

Modeling the Sloshing Phenomena of Fuel using LS-DYNA

Multiphysics Modeling

The sloshing phenomena is defined as the movement of a free fluid in a space or tank. Sloshing of fuel in a tank of an aircraft can cause dynamic disturbances that can affect the functionality of the operational system. This work examines two industrial real-life sloshing problems. The first example is the sloshing of fuel in a satellite tank. This can arise from the operational maneuvers of the satellite, which in turn can cause significant inertial forces that may lead to the decrease in performance of the satellite even up to the point of control loss. Another example concerns the slag liquids that may accumulate during the combustion process and acceleration phase of the rocket. These liquids can undergo sloshing which may narrow the nozzle opening and affect the motor performance and mission success. This work presents the attempt to model these sloshing phenomena using the most appropriate LS-DYNA solver. An overview of the available FSI solvers are presented and test cases are done in order to define the most appropriate way to model these real industrial sloshing problems.

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Yoav Lev
Rafael ltd

October 22, 2024 03:10 pm

Certification by Analysis: A discussion of solver requirements

Simulation Methods II

In recent years the fidelity of finite element models in structural mechanics has reached a remarkable quality and level of predictiveness. Hence, the question arises, if these models could even be more than the digital twin during product development: Could they be also used for homologation and certification of the corresponding products through the respective authorities or regulators as well? This idea is often referred to Certification by Analysis (CbA) or Virtual Testing (VT). It should be noted that in different industries various steps towards these goals are already taken.   The respective virtual testing procedures (including certification and homologation by regulators) require additional attention: Method development for solver enhancements needs to ensure data as well as IP protection of all stakeholders and provide measures to prevent data manipulation possibilities before homologation and market launch of the product. There are various technical as well as legal aspects to the whole process. But it needs to be emphasized that one key ingredient will be the ability of the solver to protect and safeguard input and output data while at the same time allow for traceability and transparency through fingerprinting technology when it comes to data sources like i.e. material properties, geometrical data, solver settings like version, solution method and contact parameters. Clearly, these requirements can only be met by new solver enhancements.   The present talk will target the big picture of CbA, show the route to achieve some of the most pressing issues and showcase a proposal for a first step into new solve features. This approach will be exemplified by the new Euro NCAP Virtual Far Side Simulation & Assessment regulation for occupant safety.

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Andre Haufe
DYNAmore / An Ansys Company

October 22, 2024 03:15 pm

Break

Meals

October 22, 2024 03:30 pm

Exterior Lighting Design Capabilities: How to Simulate the Latest Lamp Technologies

Electronics and Lighting

The design of automotive lighting requires a deep understanding of optical, thermal, electronics, and structural domains to comply with stringent legal requirements. The complexity of automotive lighting systems and the integration of their subsystems necessitate feedback across these different physics domains. This presentation will address several key aspects, including the optical design considerations of automotive lighting, which involve optical design principles, light source creation, materials definition, and the integration of data across various software platforms. It will also explore the capabilities of automotive lighting in validation and optimization, aiming to enhance product workflows while reducing costs and time to market. Furthermore, we will illustrate how high-fidelity computer simulations can be utilized to understand the effects of these physics domains and their interactions on automotive lighting design, which is crucial for achieving operational success, refining design decisions, and accelerating the product lifecycle.

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Akshay Patke
Ansys

October 22, 2024 03:30 pm

Update on Ansys Solutions for Structural and Durability (Mechanical)

Digital Engineering

Structural simulation and Durability prediction is paramount to next generation vehicle validation which ensures the reliability, safety, and performance of vehicles under various conditions like different loading conditions, environments, and usage scenarios. Electrification, rapid technology advancements and shorter product development cycles demands rapid advancements in simulation best practices in a form of new modeling & meshing practices, different connection types, innovative simulation workflows, solver accuracy, performance, high performance computing, incorporation of manufacturing aspects into simulation, test correlation at different stages and ability in running end to end durability workflows to automate process of durability performance improvement. In this presentation, we will show how Ansys structural and durability solutions will help deliver next-generation vehicles that provide a safer, more comfortable passenger experience. We will cover different approaches customers are adopting both solver and workflow perspectives for component, system and vehicle level simulations.

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Hardik Shah
Ansys

October 22, 2024 03:30 pm

Advancing Software Safety through Test Automation using Advanced Engineering(SCADE) and Gen AI Tools

Safety and Systems

Advanced software engineering tools can be used to generate test cases and test case sets of inputs and expected results.  Leveraging generative AI as well as traditional advanced software engineering tools enables engineers to develop test and certify safety critical software in new and more efficient ways.  This presentation will go through a journey of the tools and techniques of developing test cases of Natural language processing and software testing automation focusing on efficient methods and commercial software tools.

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Luke Zeleznak
Honeywell Aerospace Technologies

October 22, 2024 03:30 pm

Self-Driving Car Safety Through Accurate Simulation at Scale

Electrification and ADAS

Join us for an exclusive presentation where Ansys unveils the future of highly automated driving. Discover how we tackle the engineering challenge of ensuring safety across diverse scenarios through model-based systems engineering. Our approach to safety encompasses design integration, verification and validation, and incremental safety case development, all supported by advanced simulation and analysis. You will also gain insights into Ansys's commitment to safety and simulation at scale, highlighted by an exclusive testimonial from OEM customers introducing the 'Personal Pilot L3' in the new BMW 7 Series.

 

During the presentation, you will learn how to effectively integrate safety into design and verification processes, navigate system limits with a focus on safety and SOTIF (Safety of the Intended Functionality) during development and validation, and utilize synthetic sensor data for perception machine learning and AI training and validation. Additionally, you will explore how to leverage simulation at scale to validate autonomous driving features, including sensitivity and reliability analysis in scenario-based simulations.

Keywords include simulation, virtual testing, toolchain, sensor, functional safety, SOTIF, safety case, MBSE (Model-Based Systems Engineering), synthetic data, machine learning, AI, radar, camera, lidar, ultrasonic, sensor fusion, and cloud.

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Tony Karam
Ansys Inc

October 22, 2024 03:35 pm

Coupled Mechanical-Electrical-Thermal Behavior of Batteries: Experimental and Numerical Analysis

Battery/Electric Vehicle

With the increasing popularity of electric automotive vehicles, electric vertical take-off and landing (eVTOL) aircraft, and commercial drones, there is a subsequent increase in the need to better understand and predict the mechanical behavior of batteries during crash and impact events. A plasticity model of the cylindrical metal casing of commercially available batteries is developed through mechanical testing. The plasticity model is then validated by simulating the mechanical tests with LS-DYNA, which is then used to simulate crush tests on full batteries to determine the mechanical response of the inner battery components. Future work includes using LS-DYNA to accurately predict the coupled mechanical, electrical, and thermal response of batteries to prevent unwanted battery ignition during vehicle and aircraft crashes.

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Nathan Spulak
The University of Alabama in Huntsville

October 22, 2024 03:35 pm

Parametric ROM technology for fast optimization of Crash Problems

Machine Learning

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Sridhar Bijjala

October 22, 2024 03:35 pm

Simulating Safe Landing : A Deep Dive into Parachute Inflation and Float with LS-DYNA

Multiphysics Modelling 

Parachutes for aerospace application is a new research area in the current era of space science. The scope of our project includes parachute design and inflation techniques. The current research project focuses on the following application areas: ● Parachutes for Re-entry Capsule ● RLV Parachutes Parachutes are used as aerodynamic decelerators in airdrop systems, so inflation is a significant fluid-structure interaction (FSI) phenomenon. New patterns of parachutes are constantly being developed and tested for airdrop systems but this research into parachute inflation is heavily reliant on historical experimental data. Till now, no parachute inflation model that is not based on this experimental data was developed. Material and instrumentation have changed significantly since the early experimental testing, yet the methods to develop the parachutes can still be traced to the same techniques used over ninety years ago. Rapid development of computational technology and modern computational mechanics combined with numerical simulation techniques have become more widespread in parachute research field and would enable us to develop the parachutes that are more optimized. Simulating the landing of a vehicle on water using LS-DYNA is a complex task that involves the interaction between the fluid (water) and the structure of the vehicle. This type of simulation is crucial for vehicles designed to land on water. The process typically involves several steps and requires specialized techniques within LS-DYNA.

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Chandra Sekhar Kattamuri
CADFEM India

October 22, 2024 03:35 pm

Fluid Slosh Behavior For Crashworthiness A Modeling Approach Validated With Experimental Data

Simulation Methods II

October 22, 2024 04:00 pm

Interior Lighting, Cockpit Glare and Reflection Optimization

Electronics and Lighting

Vehicle vision ergonomics are becoming more and more relevant in todays automotive market. The comfort and safety of the passengers in a vehicle might be affected by different natural and artificial light sources. Interior lighting, sun reflections, displays and external lamps must be taken into consideration during the development of an optimum cabin. The human factors are no longer a subjective topic, and thanks to Ansys Speos and its virtual human vision capabilities, an infinite number of scenarios can be assessed, and a robust design can be achieved.

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Victor Loya
Ansys

October 22, 2024 04:00 pm

ADAS Sensor Models (AVx Sensors)

Electrification and ADAS

ADAS/Autonomous vehicle Software is very complex as SAE level 5 autonomous vehicle probably will have 1B SLOC vs 14 M SLOC in Boeing Dreamliner (As per Bloomberg energy report). Testing of such complex software is challenging and also time consuming. Product quality and maturity for such high complex ADAS/AV is function of testing at various levels like SW testing, integration testing, System Qualification Testing and vehicle testing. With conventional approach ADAS features get tested only at fag end of the project as it requires availability of vehicle with fully equipped sensors and actuators needed. This is extremely risky for meeting the stringent quality standard of safety critical systems, and extremely expensive. With development and maturation of artificial scenario and sensors simulation, Virtual Validation is gaining prominence as it address all demits of conventional development and testing approaches and gives edge by left shifting features testing along side of SW development. With increasing fidelity of simulation and realistic visual orchestrations, feature function testing gets left shifted and performed at bench level and use vehicle to measure Key Performance Indicators. With developments on physics based Radar model from companies like Ansys (AVx) enable configuration of antenna properties and give out ADC signal level data Virtual RWUP will gain prominence and minimize expensive Real World user Profile tests (RWUP) in real vehicle, and also enhance coverage of testing towards Safety of Intended Functionality (SOTIF) standards. Smart tradeoff between tests segregation between vehicle and simulation, makes projects execution faster, and cost effective.

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Venkatesulu Bhajanthri
Aptiv

October 22, 2024 04:00 pm

NVIDIA's AI Solution for CAE Tools

Digital Engineering

NVIDIA Modulus is a state-of-the-art, open-source scientific machine learning platform that enables research, development and deployment of surrogate ML models for a wide range of engineering applications, such as external aerodynamics, cabin cooling, electro thermal cooling simulations etc. The platform offers training pipelines that enable development of optimized and scalable end-to-end workflows for ingesting large simulation datasets, training models in a distributed manner on multiple GPUs, physics-based validation and ease-of-deployment. It offers unique tools for embedding physical constraints derived from governing equations into ML models to increase their robustness and accuracy state-of-the-art model architectures. It also offers specialized ML model architectures that cater to specific engineering applications. In this talk, we will demonstrate these capabilities of the NVIDIA Modulus platform to Develop end-to-end training pipeline for building surrogate models Show the benchmarking workflow to evaluate and validate different model architectures This will be demonstrated in the context of two use cases external aerodynamics and structural analysis of cars.

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NVIDIA

October 22, 2024 04:00 pm

Reducing Software Verification Lead-time with SCADE Model Coverage Analysis for Safety Critical Systems

Safety and Systems

Among aircraft systems, the Fly-by-Wire (FBW) system is one of the most safety critical and it matures throughout the flight test campaign. During the campaign, many software loads are released, and several software verification activities must be satisfied before each of those software loads are allowed to be flown. At EMBRAER, SCADE has played a pivotal role for over 15 years in allowing the quick deployment of FBW software releases used throughout all its business units.   The latest version of SCADE is being used by EMBRAER in the development of the FBW for EVE - a leader in EVTOL industry. The brightest new feature in this latest version is SCADE Model Coverage Assistant (MCA), which is being used for the first time. This discussion will describe how EMBRAER believes how SCADE MCA will considerably alleviate verification activities and reduce software lead-times during the most strenuous phase of the aircraft development.

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Charin de Silva
Embraer

October 22, 2024 04:00 pm

Exploring Ansys LS-DYNA's Battery Modeling Capabilities

Battery/Electric Vehicle

Over the past decade, considerable advances have been made on battery safety models but achieving predictive accuracy across a wide range of conditions continues to be extremely difficult. From a numerical perspective, the obstacles are numerous.   Multiple physics can potentially be involved and interact with one another, electrochemistry, thermal, mechanical, fluid dynamics and so forth. The question of modeling scale also invariably arises. Is it reasonable to imagine a numerical model resolved at the micro scale being later used in a macro model such as car crash simulation?   LS-DYNA was initially approached by several actors in the automotive industry in order to develop simulation tools that would eventually allow an engineer to design a Multiphysics model for a battery pack or module that could be run as a stand-alone simulation or, later on, be included in different crash simulations at a reasonable cost. Several developments have emerged from this original ask, that are present in LS-DYNA and available to all users and engineers interested in the broad aspect of battery simulation.   In this paper, modelling techniques for the mechanical aspect of battery simulation (eg material laws), will be discussed. The BatMac module, a part of the LS-DYNA EM solver used to capture internal and external shorts will be introduced up to and including the initial heat generation, thermal expansion, and thermal runaway modelling. Validation results and workflow examples will be given. Finally, topics that are of contemporary interest to battery simulations such as busbar thermal expansion, swelling, or venting will be discussed.

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inaki Caldichoury
ansys

October 22, 2024 04:00 pm

From automatic event detection to automatic cause correlation

Machine Learning

N. Abdelhady1, D. Borsotto1, V. Krishnappa1, K. Schreiner1, C.-A. Thole1, T. Weinert1 1SIDACT GmbH Reaching and fulfilling several design and crash criteria during the development process is what makes the engineer adapt and redesign the simulation model over and over again. Ideally resulting in new simulation runs with in best case improved performance, matching the intention of the applied changes. For the more demanding case of unforeseen results which do not necessarily fit to the expectations of the actual changes, machine learning methods and a workflow are being introduced here, which allow to identify the root cause of this behavior.  In a first instance every new simulation run is being added into an analysis database, which is continuously being used to compare new simulations against. Previous studies have already shown that this process can assist the engineer in automatically highlighting new behavior and pin pointing the engineer to the regions of interest. Rather than only highlighting the new behavior now a second phase is being triggered additionally.  In this second phase the previously detected event is being isolated and analyzed against the gathered data of the development history. The analysis methods used are based up on the Principal Component Analysis, a reduced order modelling technique. This allows not only identifying structures in the data but also correlating deformation patterns against each other. Especially the latter one is of interest for an automated process, as it allows automatically detecting and suggesting possible root causes to the engineer. As an outcome of this process the engineer receives a list of correlating parts, so that he can focus on deriving a better engineering solution to achieve a deterministic behavior, rather than searching for the root cause of the event.  To provide additional information about the type of cause, as for example failure or buckling, the identified parts are also forwarded to a classification prototype. This type of classification shall assist the engineer in deriving a possible design adaptation.

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Dominik Borsotto
SIDACT GmbH

October 22, 2024 04:00 pm

Enhancing FSI Simulations in LS-DYNA: Implementing Immersed Interface Techniques in the Incompressible CFD Solver

Multiphysics Modeling

This paper focuses on implementing immersed interface techniques within the Incompressible CFD (ICFD) solver in LS-DYNA. For Fluid-Structure Interaction (FSI) simulations, immersed methods offer several advantages: they simplify the pre-processing stage, prevent large mesh distortions due to structural motion, and provide more robustness in scenarios involving complex contacts. However, these methods sacrifice accuracy in near-wall regions, suggesting that a hybrid approach between body-fitted and immersed methods could be beneficial in some cases. This work discusses two methods: the Resistive Immersed Implicit Surfaces (RIIS) method [1] and a method based on a new set of discontinuous finite element functions [2]. The basics of these methods will be presented, along with considerations for setting up a model in LS-DYNA, including pre- and post-processing.  [1] Fernandez MA, Gerbeau JF, Martin V (2008) Numerical simulation of blood flows through a porous interface. ESAIM: Mathematical Modelling and Numerical Analysis 42(06): 961-990. [2] R. Zorrilla, R. Rossi, R. Wüchner, E. Oñate, An embedded Finite Element framework for the resolution of strongly coupled Fluid-Structure Interaction problems. Application to volumetric and membrane-like structures, Computer Methods in Applied Mechanics and Engineering, Volume 368, 2020, 113179.

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Facundo Del Pin
Ansys

October 22, 2024 04:00 pm

Modular Contact: A new approach to contact in LS-DYNA

Simulation Methods II

The "Modular Contact" is a new implementation of contact algorithms in LS-DYNA. We will give a short overview of the fundamental ideas behind it and how it tries to achieve its main goals: a more uniform implementation between different contact options and improved (parallel) performance by better harnessing of modern hardware and improved MPI communication. The performance will be demonstrated on large models and put in comparison to the well-established, existing algorithms in LS-DYNA.

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Albert Ziegenhagel
Ansys

October 22, 2024 04:25 pm

Modeling Battery Safety under Penetration Loads Using LS-DYNA

Battery/Electric Vehicle

The safety of battery systems in electric vehicles (EVs) and portable electronics under impact or penetration is critical. Traditional modeling methods, relying on simplified approaches, fall short in capturing complex interactions and dynamic behaviors. Advanced simulation techniques using LS-DYNA offer more accurate predictions of battery responses to penetration loads. This abstract outlines recent methodologies employing LS-DYNA for high-fidelity modeling of battery components and protective measures. Innovations include sophisticated material models for electrodes, electrolytes, separators, and structural packaging. These advancements align with standards like SAE J264, ensuring battery safety and reliability, thereby supporting the adoption of electric mobility and renewable energy technologies.

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Satish Kumar Meenakshisundaram

October 22, 2024 04:25 pm

LS-OPT Pro: Status and Outlook

Machine Learning

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NIELEN STANDER
Ansys LST

October 22, 2024 04:25 pm

New porous media model for high-speed flows and EnSight-specific postprocessing output in the dual-CESE solver in LS-DYNA

Multiphysics Modelling

October 22, 2024 04:25 pm

New Advances in the Discrete Element Method (DEM)

Simulation Methods II

In the last three decades, DEM (Discrete Element Method) has been extensively developed and applied to solve many geotechnical and petroleum engineering problems. Another approach is developed to account for the elastic and brittle behavior of materials. The method has been successfully implemented in the LS-DYNA to study cementitious, sintered, and rock materials such as concrete, fibers, rocks, etc.  Explosives with the combination of rock, concrete, and other brittle materials are simulated using LS-DYNA and studied extensively by researchers. In such cases, the volume of the fragments and number of fragments would be beneficial to the researcher. To assess this, we have developed a system that computes the number of fragments, fragment volume, and number of bond links associated with the DEM particles. Users have the option of outputting the results described above, depending on the user control card by using *DATABASE_DEFRAGMENT.  Additionally, DEM has been extended to simulate the likes of intumescent material through new keyword *DEFINE_DE_TEMP. The DEM formulation has been extended to include the temperature effect on the radius of DEM particles. The method takes the user’s temperature with several inputs and expands the radius of the particle based on the temperature and coefficient of thermal expansion. With recent improvements, the DEM can be thermally coupled with the Finite Element Method (FEM), and particles can change size in response to temperature changes in the DEM. The new improvements allow for the simulation of complex thermal behavior in a variety of real-world scenarios, like soil interaction with a blasting battery, a heated container containing discrete material etc. Users can activate thermal conductivity of the DEM by providing the required data in the DEFINE_DE_BY_PART, CONTROL_DEM, and DEFINE_DE_TO_SURFACE_COUPLING. The LS-DYNA/MPP decomposes the problem once based on its initial geometry. For good MPP parallel efficiency, the deformation of the geometry should not be too large to keep reasonable ratio between computation and communication time. However, most DEM problems are dealing with granular flow which involve mixing and large relative displacement between particles. The parallel efficiency degrades due to increasing data communication. A re-decomposition algorithm supports DEM features which can reduce computing costs by 30%. This algorithm would rearrange the grouping of the particles, thus avoiding the search for neighbors that are far away from the group. A Galerkin meshfree method can generate shape function without the need of element or mesh, allowing it to provide a quality solution for large deformation problems such as fragmentation, cracks, material separation etc. The shape function in the meshfree method is rational function with complexity and because of this the domain integration scheme becomes challenging. Over the last 2 decades, several integration schemes were developed to obtain a computationally efficient and stable solution. Few methods can resolve the stability related issues and the efficiency; However, the meshfree methods are still computationally expensive due to the requirement of the higher support size.  To address this issue a novel method, namely Expedited Galerkin Meshfree Method (EGMM) is developed. The method employs a nodal integration with a unique stabilization scheme to stabilize the solution at lower support size. The method only needed a minimum evaluation point and does not require direct second order derivative of the shape function. The method achieves its objectives by stabilizing the Galerkin solution with minimum computational cost. The resulting method conserves the linear momentum and the total energy. The contact between the two bodies or the particles can be easily implemented by integrating with the Discrete Element Method. Overall, the simulation result demonstrates that the method is stable and works effectively for the various types of materials. The user can define this model similar to the solids by generating solid and using *SOLID_EGMM. Numerous material behaviors are taken into consideration by using the constitutive model, which can be defined by *MAT_.

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Mohammed Mujtaba Atif
Ansys

October 22, 2024 04:30 pm

Streamlining EVs from Design to Operations with Hybrid Digital Twins

Digital Engineering

In the drive towards an electrified and sustainable future, automotive companies are increasingly adopting simulation technologies to accelerate design cycles and reduce costs. As technology complexities escalate, there is a growing need for an integrated development approach that emphasizes early-stage development and validation processes. Engineers are turning to simulation to address complex system requirements, but achieving comprehensive system validation through virtualization requires the creation of high-fidelity, physics-based plant models. These models, calibrated using machine learning and integrated with software functions and real-world driving scenarios, enable a virtual replication of the vehicle. Moreover, companies are now extending these models from product development into operational phases, leveraging the power of Hybrid Digital Twins for real-time fleet management. In this session, Ansys experts will explore the use of simulation methods, reduced-order models (ROMs), and AI/ML techniques for performance validation through model-in-the-loop (MIL), hardware-in-the-loop (HIL), and virtual drive tests. The discussion will also cover how to combine data and physics to create hybrid digital twins, which offer online insights into component operation through virtual sensors, predict service life, and optimize operating conditions. Key takeaways include understanding Hybrid Digital Twins—why and how to implement them, high-fidelity system simulation through reduced-order models, integrating test and 1D data with 3D data for accurate virtual validation, and the role of virtual sensors in predictive maintenance, all powered by physics and refined by data.

October 22, 2024 04:30 pm

Taking HUD Design to the Next Level (Speos)

Electronics and Lighting

Heads Up Display (HUD) systems present information within the driver's field of view, allowing them to keep their eyes on the road at all times. HUD systems have been around for over half a century, but a renewed interest and investment in this technology is currently taking place. This is being driven, in large part, by the advent of Advanced Driver Assistance Systems (ADAS) where the need to display safety-critical information effectively, with minimal distraction, is essential. To keep up with the growing demand and complexity of HUD systems, engineers need a fast and effective way to design, optimize, test, and validate them. This includes defining functional specifications & quality targets, assessing key performance metrics, and visually perceiving the system as the driver would. Ansys optical solutions provide purpose-built tools and workflows to virtually design, assess and test a HUD prototype under various driving conditions. This presentation will demonstrate how optical simulation and virtual prototyping can help solve the challenges of HUD design.

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TJ Gilleran
Ansys

October 22, 2024 04:30 pm

Safety and Systems Track: Session to be Announced

Safety & Systems

October 22, 2024 04:30 pm

Image Injection HIL Solution for Adaptive Driving Beam Development and Testing

Electrification and ADAS

This joint presentation by Jeff Blackburn of Ansys and Chris Manning of dSPACE will discuss the new FMVSS-108 Adaptive Driving Beam (Smart headlamp) regulations, and how SiL and HiL simulation can be used to greatly reduce the need and inconvenience of track and road nighttime physical testing, saving time and money Integrating the Ansys AVx physics accurate camera and headlamp models with the dSPACE ASM 3D driving simulator and vehicle dynamics models yields a SiL virtual twin of your vehicle and ADB exterior lighting system allowing you to test your ADB headlamp function and control logic virtually on the desktop. 

Using a dSPACE HiL bench with an ESI (environmental sensor interface) module, the Ansys AVx simulation generated raw image frames can be directly injected into the real camera’s image processing chip. This let’s you test the ADB headlamp function and control logic using the real camera’s perception software in the convenience of the lab, versus having to send your engineering team out at night.

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Jeff Blackburn
Ansys, Inc.

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Chris Manning
dSPACE Inc.

October 22, 2024 04:50 pm

Scaling from Battery Cell to Electric Vehicle (EV) Crash - A Case Study from Full Vehicle Teardown

Battery/Electric Vehicle

As EVs become more mainstream safety concerns have been paramount for OEMs, consumers and regulators. Owing to the risk of thermal runaway in an EV crash incident, a full Multiphysics battery analysis is required to capture the mechanical deformation that triggers internal shorting and thermal runaway.  This is helpful in knowing the mechanical design limits and designing vehicles with good crashworthiness while balancing the need to lightweight EVs as car companies strive for better range.   Ansys developed a simulation workflow from battery cell to vehicle level (in partnership with universities and industry test labs) to validate key pieces using physical test data from a 26Ah automotive pouch cell.  LS-DYNA models were calibrated and subsequently validated against cell experimental data. Multiphysics models that captured a battery cell's electrical, mechanical and thermal behaviors were then to used to scale up in a proof-of-concept simulation of full vehicle crash. 

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Vidyu Challa, PhD
Ansys

October 22, 2024 04:50 pm

Fully Transient Vehicle Crash Predictions powered by SimAI

Machine Learning

October 22, 2024 04:50 pm

Study of Vehicle Aerodynamics with the ICFD Solver and its Application to the Quarkus P3 Pikes Peak Version

Multiphysics Modelling

October 22, 2024 04:50 pm

Multiphysics Analysis of Automotive Components for Product Portfolio Optimization

Simulation Methods II

In this study, the pillars A, B and C from the Body-in-White (BIW) of a pickup passenger vehicle were considered, and the steels used for these components were identified based on the A2MAC1 platform, the SAEJ2947 standard, and state-of-the-art literature. Subsequently, these steels were compared with the client's product portfolio to propose a steel that meets the characteristics demanded by the automotive market for each of the components considered in the BIW. Next, the performance of each of the three pillars with these steels was validated and compared through crashworthiness simulations using Finite Element Analysis (FEA) with ANSYS LS-DYNA software. These simulations modeled the behavior of the pillars on side impact tests, with meshed parts based on the 2014 Chevrolet Silverado 1500 FEA model from the CCSA of the George Mason University. The impact speed was based on the Oblique pole side impact testing protocol from Euro NCAP; the time simulation was based on the Side impact Crashworthiness Evaluation 2.0 Rating Guidelines from the IIHS. To compare materials’ behavior, different curves were defined for each case. The tested materials were evaluated by comparing internal energy and displacement on each of the three pillars. Finally, results regarding the behavior of the different materials were discussed.

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Santiago Torres
Universidad de Monterrey

October 22, 2024 05:00 pm

Track Wrap Up: Electrification and ADAS

Electrification and ADAS

October 22, 2024 05:00 pm

Track Wrap Up: Electronics and Lighting

Electronics and Lighting

October 22, 2024 05:00 pm

Track Wrap Up: Safety and Systems

Safety and Systems

October 22, 2024 05:00 pm

Track Wrap Up: Digital Engineering

Digital Engineering

October 22, 2024 05:30 pm

Reception

October 23, 2024 07:30 am

Exhibits Open

Exhibition

October 23, 2024 07:30 am

Continental Breakfast

Meals

Walk the exhibition space to grab your quick breakfast before general session.

October 23, 2024 07:30 am

Registration

Registration Desk Open

October 23, 2024 07:30 am

HPE | AMD Invitation-Only Roundtable

Next gen CAE: Setting a new standard for product development with HPE and AMD 

To effectively support and scale their Ansys applications, manufacturers must enhance engineering productivity, become more data-driven, meet sustainability goals, scale flexibly, and increase profit margins.  Hewlett Packard Enterprise and AMD have teamed up with Ansys, the premier provider of CAE software, to help revolutionize product design. Our next-generation CAE solutions deliver virtually unlimited capacity and industry-specific tools to speed up design cycles and lower total cost of ownership (TCO). 

Join us to explore how you can optimize your CAE infrastructure for all your Ansys applications. Bring your questions and let’s shape the future of engineering together! 

October 23, 2024 07:30 am

TotalCAE Invitation-Only Roundtable

The Impact of AI/ML in the Product Development Process 

Artificial intelligence (AI) and machine learning (ML) have emerged as a potential transformative force in product development. This round table will explore the pivotal role of AI and ML in shaping the future of product design and optimization. We will delve into how these technologies streamline the speed and quality of the development process, AI/ML challenges and limitations that we can work together on addressing, and how to get started in testing these technologies. 

October 23, 2024 08:00 am

Advancing Transportation and Road Safety: GMU's Research Activities Using LS-DYNA Simulation

General Session

October 23, 2024 08:30 am

Optimization of Diastolic Material Parameters: Use of a Shape-Based Objective Function in Conjunction with a Feasibility Classifier

Biomedical/Healthcare I

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Mark Ratcliffe
UCSF

October 23, 2024 08:30 am

Modelling thick-walled aluminium extrusions in side-crash applications

Crash II

A critical consideration in the design of protective structures for electric vehicles is their energy absorption capacity. The development of lightweight structures is essential, as the range and weight of electric vehicles are intrinsically linked. High-strength aluminium structures are frequently used due to their exceptional strength-to-weight ratio and excellent mouldability. Aluminium alloys within the 6xxx series are of significant interest attributable to satisfactory performances in energy absorption applications when subjected to severe mechanical loads.  Traditionally, in the automotive sector, extruded profiles are modelled using shell elements, which are based on the plane stress assumption. This approach is generally accepted for thin-walled profiles.  In contrast, shell elements inadequately describe the mechanical behaviour of complex thick-walled structures. As the wall thickness becomes significant in relation to their length, stresses and deformations appear in the thickness direction, which could lead to the formation of out-of-plane shear cracks.  Therefore, the use of shell elements appears unsuitable for this application. Instead, refined solid element meshes and fracture models are used in these models.   In this study, the mechanical behaviour of a thick-walled multi-chamber aluminium extrusion has been investigated. Different element technologies and materials models have been evaluated based on dedicated material and component tests, trying to find a balance between accuracy and computational cost.

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Edouard Yreux
Ansys Inc

October 23, 2024 08:30 am

Study on Impact Loading Reduction Performance of "Origami Hat"

Drop/Impact Dynamics

With the enforcement of the revised Road Traffic Act, wearing helmets has become a mandatory effort for all cyclists since April 1, 2023 in Japan. However, there are still many people who do not wear helmets. Therefore, we considered developing a foldable helmet that can be easily carried by applying the concept of origami engineering. Origami engineering is a research field proposed with the aim of developing lightweight, high-strength structural components based on the idea of origami, a traditional Japanese craft in which various shapes are created by folding paper-like materials. Under the same conditions of the safety test for industrial helmets, a 5 kg striker was dropped from a height of 1.0 m onto a dummy head wearing the hat, and the impact load received by the dummy head was computed in the simulation. As a result, it was confirmed that it was possible to reduce the impact load by devising the proper material properties and folding shape.

October 23, 2024 08:30 am

Ansys Forming - The New GUI for Forming Simulations with LS-DYNA: An Overview and Outlook

Forming II

Ansys Forming is the new graphical user interface (GUI) for sheet metal forming simulations with LS-DYNA. While LS-DYNA is renowned for its precision in sheet metal forming simulations, its complexity often necessitated extensive expertise. Ansys Forming addresses this challenge by providing a user-friendly GUI that guides users through the setup process seamlessly. Developed by the same team behind the solver, Ansys Forming ensures perfect integration with LS-DYNA, facilitating all finite element (FE) related tasks. It is designed to meet the needs of method engineers, making the process more intuitive and efficient. Users can easily define operations, set up tools and their kinematics, specify the blank and material properties, select trim lines, and configure flanging operations. Additionally, determining the measurement station with all pilots and clamps to accurately calculate springback is straightforward. The analysis features of Ansys Forming empower users to thoroughly evaluate the part and process. The GUI provides tools for visualizing tool movements, formability diagrams, wrinkle analysis, surface analysis for class A panels, real sheet thickness, and contact gaps. Assessing the formability of the part and displaying springback relative to a reference part is essential for tool springback compensation. This presentation will offer an overview of Ansys Forming's functionalities and a perspective on future developments.

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Chris Robinson
Ansys

October 23, 2024 08:30 am

Application of Trimmed Solid in IGA to Aluminum Diecast Part Analysis

IGA I

To reduce the impact of automobiles on the global environment, there is an urgent need for automotive OEMs and other related companies to take initiatives such as carbon neutrality and resource circulation. As part of the use of sustainable materials, each company is considering the adoption of large-scale aluminum diecast (ALDC) parts for the purpose of integrating components and enhancing the recycling rate. ALDC could be applied to parts for which safety performance against car crashes is required. For the design of such parts, their performance needs to be predicted through crash analysis. Large ALDC parts usually contain thick walls and complex geometry, and tetrahedral elements are often used to model such parts in Finite Element Analysis (FEA). While tetrahedral elements are relatively easy to use for creating a model, they generally have poor analytical accuracy, especially when reproducing bending deformations. To achieve sufficient accuracy, models need to be subdivided adequately in the thickness direction as well as in the in-plane direction, or higher-order elements need to be used. Consequently, computational time could increase significantly compared to conventional steel sheet parts that use shell elements, due to an increase in the number of solid elements or a reduction in the time-step size. This increase in computational time hinders efficient vehicle development. One of the methods that can address the issue is Isogeometric analysis (IGA). IGA is an analysis method that employs high-order spline functions as basis functions, similar to CAD. Because IGA achieves higher continuity than C^{p-1} even at element boundaries, it provides good accuracy even with coarser elements. Additionally, analysis can be performed with larger time step sizes compared to the FEA. In bending analysis, IGA only requires one solid element through the thickness, resulting in significant computational time reduction compared to tetrahedral elements. However, a drawback of IGA is the difficulty of solid model creation, making it very challenging and time-consuming to create large and complex ALDC part models. In such circumstances, the development of trimmed solids for IGA is in progress. The trimmed solid is one of the embedded analysis methods that do not require the creation of boundary-fitted meshes strictly defining the geometry's boundaries. Consequently, the model creation is much easier than with boundary-fitted solids used in conventional IGA. Considering both model creation time and analysis time, the trimmed solids are expected to have a significant impact in crash analysis. However, its application in industry is still limited, and to the best of the author's knowledge, there are no examples yet of its application in vehicle crash analysis. In this presentation, we will introduce some application examples of trimmed solids for ALDC parts analyses. First, a simple bending analysis was conducted to evaluate the load response and confirmed its accuracy. Subsequently, more analyses were performed on complex parts. The results confirmed that computational time was significantly reduced compared to conventional FEA, while maintaining accuracy. Additionally, we will discuss some remaining issues during the presentation.

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Tadashi Naito
Honda Motor Co., Ltd.

October 23, 2024 08:30 am

Advancements in Humanetics' FE Models

Occupant and Pedestrian Safety II

October 23, 2024 08:30 am

Digital Transformation and MBSE Workshop

Join us for an in-person hands-on workshop as we aim to explore solutions for digital transformation initiatives. Discover the tools to optimize processes faster with greater efficiency, and be inspired to design, build, and work in new ways. Gain insight into how digital transformation challenges are being addressed with innovative solutions by thought leaders and industry experts. Attendees are asked to bring a laptop for the hands-on portion of the Workshop.​

8:30 AM - 8:45 AM Welcome/Opening  
8:45 AM – 9:15 AM Industry guest speaker 
9:15 AM – 10:10 AM MBSE Hands-on workshop - part 1 
10:10 AM - 10:30 AM Break
10:30 AM - 12:30 PM MBSE Hands-on workshop - part 2 
12:30 PM - 1:00 PM Lunch
1:00 PM - 1:30 PM MBSE Hands-on workshop - closing

October 23, 2024 08:30 am

Digital Safety Workshop

Join us and the industry leaders from automotive and semiconductors in this in-person hands-on technical workshop focused on model-based safety analysis. We recommend the participants who plan to join bring their laptops for the hands-on experience.

8:30 AM – 8:45 AM Welcome/Opening  
8:45 AM - 9:15 AM Guest speaker - CS Group 
9:15 AM - 10:10 AM Safety Collaboration Platform 
10:10 AM - 10:30 AM Break
10:30 AM - 12:10 PM DSM and Safety Cases 
12:10 PM - 1:15 PM Lunch
1:15 PM - 2:30 PM Digital Engineering at Ansys 
2:30 PM - 3:00 PM Break
3:00 PM - 4:00 PM AI for safety and cybersecurity analysis 
4:00 PM - 5:00 PM Safety of AI 
5:00 PM - 5:20 PM Wrap Up & Closing

October 23, 2024 08:30 am

Embedded Software Workshop

Join us and the industry leaders from automotive and semiconductors in this in-person hands-on technical workshop focused on model-based safety analysis. We recommend the participants who plan to join bring their laptops for the hands-on experience.

8:30 AM – 8:45 AM Welcome/Opening  
8:45 AM - 10:10 AM Hands-On Workshop Part 1: Architecture and Design of Embedded Software 
10:10 AM - 10:30 AM Break 
10:30 AM - 11:00 AM Academic Guest Speaker (UNAQ): Adoption of SCADE in a Full Academic Program 
11:00 AM - 12:00 PM Hands-On Workshop Part 2: Software Implementation and Verification 
12:00 PM - 1:15 PM Lunch 
1:15 PM - 1:45 PM Hands-On Workshop Part 3: System / Software Integration 
1:45 PM - 2:30 PM From Fail-safe to Fail-operational: Model-Based Solutions for Automotive Embedded Controls of the Future 
2:30 PM - 3:00 PM Break 
3:00 PM - 4:00 PM Hands-On Workshop Bonus: Ansys Innovations with Scade One 
4:00 PM - 4:30 PM Wrap Up & Closing 

October 23, 2024 08:55 am

Design Evaluation of an Ortho-Chair for the Prevention and Relief of Lower Back Pain

Biomedical/Healthcare I

October 23, 2024 08:55 am

Simulated Failure Limitations of Midwest guardrail System

Crash II

October 23, 2024 08:55 am

More than 40% cost reduction through drop test simulation with Ansys LS-DYNA

Drop/Impact Dynamics I

October 23, 2024 08:55 am

Die Hemming Simulation with Ansys Forming and LS-DYNA

Forming II

October 23, 2024 08:55 am

Evaluation of B-Pillar crush using IGA Shells

IGA I

Iso Geometric Analysis (IGA) uses higher order and higher continuity splines to represent the geometry and the solution field. This enables the use of more accurate geometry representation, higher solution accuracy and a larger timestep size compared to traditional Finite Element Method (FEM).  In this study, IGA shells are used to simulate the B-Pillar crush and the results are compared with FE mesh and physical test results. Both the B-Pillar displacement as well as the platen force are predicted reasonably accurately by the IGA model. Since all legacy material models, contact and connection techniques can be used with IGA without any change, a Hybrid modelling approach can be used for vehicle crash models where the IGA shells can be included for critical parts where higher accuracy and better crush prediction is desired.

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Amruta Raut
Stellantis

October 23, 2024 08:55 am

Enhancing Vehicle Safety Assessments through Advanced Virtual Testing Crashworthiness with the aid of ANSA and META

Occupant/Pedestrian Safety II

The automotive industry is continually evolving to meet stringent safety standards and enhance occupant protection in crash scenarios. With Euro NCAP supplementing far-side impact testing with Virtual Testing Crashworthiness (VTC) starting in 2024, real tests and CAE simulations come closer more than ever. The VTC protocol mandates the use of simulation and physical test data to robustly evaluate far-side impact protection, requiring detailed compliance with validation and quality criteria, as well as specific data formatting for submission. Consequently apart from far-side more protocols will be implemented in the virtual testing raising more challenges to the safety engineers. As a result there is an increasing need for efficient tools that streamline the assessment process offering ‘know how’ of the different protocols and simultaneously minimize the human interaction with the aid of automation. This paper introduces the solutions that BETA CAE has come up with, in order to bridge CAE with real testing covering all the current but also the future needs of VTC. In ANSA the pre-processor a new tool has been introduced that automates the ATD/HBM positioning process following the specifications of each protocol or utilizing experimental data coming either from posture landmarks or scanned STL meshes. Along with the already known in the market, seat positioning, seatbelt and impactor tools form a complete suite to ensure an easy and proper preparation of the model for ANSYS LS-DYNA safety simulations. Additionally, an innovative software tool has been integrated within META, BETA CAE Systems post-processor, designed to meet and exceed the requirements of the Euro NCAP VTC protocol. The tool offers comprehensive functionalities to facilitate the evaluation process, ensuring accuracy, efficiency, and compliance. Key features of the tool include the ability to read and process all necessary LS-DYNA simulation and physical test results, and export the data in the ISOMME format with precise adherence to protocol requirements, ready to be uploaded to the Euro NCAP website. Additionally, the tool performs pre-assessment in the same manner as Euro NCAP, allowing automotive manufacturers to know their potential rating before submitting the results officially. This pre-assessment ensures that manufacturers can refine their designs to achieve the desired safety ratings. By automating the critical aspects explained above, the aforementioned tools significantly reduce the time and effort required for vehicle safety assessments. They ensure that automotive manufacturers can efficiently comply with the latest Euro NCAP standards and beyond, ultimately contributing to the development of safer vehicles.

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Thanassis Fokylidis
BETA CAE Systems SA

October 23, 2024 09:20 am

Simulation workflow for Transcatheter Aortic Valve Replacements: From crimp and deployment to fluid-structure interaction

Biomedical/Healthcare I

The design of a stent frame for transcatheter valve replacements is a challenging task as treatment preparation and deployment have an influence on the final shape and performance of the device. Moreover, a complicated fluid-structure interaction load case is required to assure optimal performance of the valve and to predict stresses and strains in the frame for fatigue life assessment. Typically, one distinguishes between balloon-expandable frame designs mostly made of stainless steel or self-expandable frame designs made of nitinol as shape memory alloy. The focus of this contribution is on self-expandable frames and all simulations are based on a mockup geometry of the Evolute-R System of Medtronic, which is frequently used in literature. The goal of this presentation is to set up these simulations such that they can be connected in an automated workflow. Simulation steps include a crimping simulation of the stent frame into a delivery capsule as well as a micro catheter insertion simulation into the anatomy to determine a good initial position for the deployment simulation of the device into the anatomy. After the device is properly deployed, fluid-structure interaction simulations are carried out to assess the performance of the valve. With such a workflow, these simulations can be repeated at different implant depths to find a position where the performance of the valve is optimized or even repeat the simulations for other anatomies. This will allow design engineers in industry to quickly assess design ideas under real-life loading conditions. A simplified user interface of the workflow will democratize these complicated simulations to make them available to clinicians to check the optimal sizing and positioning of the device.

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Nils Karajan
DYNAmore, An Ansys Company

October 23, 2024 09:20 am

Leveraging Graph Neural Networks for Surrogate Model Development in Automotive Crash Simulations

Crash II

October 23, 2024 09:20 am

Accidental Fuel Drop on Spent Fuel Pool Storage Racks

Drop/Impact Dynamics I

October 23, 2024 09:20 am

A systematic study on Ansys Forming performance

Forming II

Mesh adaptivity refines the blank mesh as needed in stamping simulations. Users do not need to anticipate where a dense mesh will be required. Despite its universal use, it demands significant effort due to serialization and the need to carry a dense mesh through subsequent iterations. In-Core adaptivity and Mesh fusion assist the solver in conserving effort, thereby enhancing performance. This paper will demonstrate best practices for utilizing In-Core adaptivity and Mesh fusion in Ansys Forming through practical cases. In addition, for different model, we should find an optimum number of CPUs to run the job. Beyond this number, the scalability will not see any obvious improvements.

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Kang Shen
Ansys

October 23, 2024 09:20 am

Recent Enhancements and Studies of Isogeometric Shells in LS-DYNA

IGA I

Isogeometric Analysis (IGA) [1] is a Finite Element Analysis (FEA) technology that uses spline basis functions known from Computer Aided Design (CAD) to describe the geometry and the solution field. Employing such spline basis functions with higher order and higher continuity may yield several advantages such as an easier transition from CAD to analysis, a more accurate geometry description, smooth solution fields or a larger time step in explicit analysis. In fact, only the higher-continuity property of splines enables the concept of trimming (ubiquitous in CAD) to be used in explicit analysis with a feasible time step size [2].  Over the last years, the trimmed IGA shell capabilities of LS-DYNA were consistently enhanced and reached a high level of maturity [3,4] as demonstrated in a recent study by Bauer et al. [5]. In that study, a Body in White was modeled with hundreds of trimmed IGA shell components (using ANSA [6]) and successfully implemented in hybrid IGA/FEA full vehicle crash simulations.

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Lukas Leidinger
DYNAmore GmbH, an ANSYS company

October 23, 2024 09:20 am

Mitigating Risks at Bus Stops: A Study of the Effectiveness of Bollard Systems

Occupant/Pedestrian Safety II

All major metropolitan areas are served by a complex network of public bus transit services with thousands of transit stops, serving millions of passenger trips, including a large number of riders with wheelchairs or bicycles. The safety of bus network patrons and employees is critically important, especially while onboard transit vehicles and at transit stops. Although most metropolitan bus services have a good overall safety record, several bus stops are struck by motor vehicles each year. Fortunately, most of such incidents do not result in significant fatalities or major injuries. However, it is important to enhance the safety of bus stops through proactive measures to mitigate vehicle crash risks. These measures not only provide a safe space for passengers but also protect the bus stop shelters. This work considers the use of bollard systems to protect transit stops. The main objective of the study is to assess the effectiveness of a proposed interconnected multi-bollard design in protecting bus stop occupants from vehicular impacts.  An analysis was conducted to determine the efficacy of this system in stopping oncoming vehicles, and the potential effect of the crash on the driver. A detailed model of a 3-bollard system was developed in Ansys LS-DYNA. This model included the bollards, their underground support structures, and the rebars connecting the bollards. The bollard system was composed of 116 parts with a total of 443,799 elements. The bollard system model was merged with a detailed model of a 2007 Chevrolet Silverado, 4-door crew cab pickup truck. The vehicle model has 603 parts with 251,400 elements. The vehicle was simulated to impact the bollard system at speeds between 15 and 90 mph at angles ranging from 0 degrees (normal to the bollard system) and 90 degrees (parallel to the bollard system). Impacts were also made at various degrees of centeredness, with cases showing response from impact at the center of bumper, as well as at the edge of the bumper. With each case, vehicle velocity and acceleration were monitored using virtual accelerometers, placed in the vehicle to assess the effectiveness of the bollard to stop the vehicle and the potential of driver's injuries. Simulation results show that the bollard was able to stop a vehicle traveling normal to the bollard system, impacting the center of the bumper at speeds up to 45 mph. However, the vehicle would continue past the bollard system at higher speeds. The study also discusses the effect of the vehicle impacting the bollard system at different angles and at different off-center locations.

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Jonathan Lazatin
UNLV

October 23, 2024 09:45 am

Introducing J-SimRapid, A New Reduction Modelling Tool for Vehicle Crash Simulation

Crash II

Demands for ever increasing efficiency of automotive crash analysis have continued to rise in the drive to reduce automotive development costs. When major design changes are required to satisfy product performance late in the development process, significant cost and time are required to implement them. To alleviate this, automotive manufacturers have adopted the concept of "front-loading" to identify problems early-on in the development process. The earlier issues in the production phase can be identified, the more efficiently and effectively development can be performed. JSOL Corporation has developed a new method for modelling automotive body structures to simulate crash analysis in the early stage of design that employs Hughes-Liu beam elements with arbitrary cross-sectional geometry. Then JSOL Corporation has released a new modelling tool J-SimRapid that can easily create the reduction models. This tool enables front-loading crash safety analysis in the conceptual design phase. Furthermore, it can also reduce large-scale models in the detailed design phase. Consequently, J-SimRapid makes overall automotive design phases more efficient. In this presentation, the new model reduction method will be introduced along with examples of reduced model analysis by J-SimRapid.

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Shinya Hayashi
JSOL Corporation

October 23, 2024 09:45 am

Sequential drop test simulations through automated process in Workbench LS-DYNA

Drop/Impact Dynamics I

October 23, 2024 09:45 am

3D Drawbead Design and Mesh Regeneration in Ansys Forming

Forming II

In ANSYS FORMING, we have developed innovative techniques for predicting drawbead forces and generating 3D drawbead geometry to streamline the drawbead design process, which is crucial for controlling material flow in stamping processes. These tools include a drawbead profile generator, a simulator, and a 3D drawbead generator. The profile generator creates custom drawbead profiles based on sectional design parameters, while the simulator estimates restraint and uplift forces through a strip drawing test. The 3D drawbead generator automatically creates 3D drawbead meshes from single or multiple drawbead profiles for both closed and open beads, enabling accurate material flow estimation in 3D high-fidelity stamping simulations. In addition, we introduce an innovative surface mesh regeneration method based on adaptive quadtree refinement to address issues of distorted or skewed initial meshes. This method intelligently refines regions with complex features or high gradients that require higher resolution, while discretizing smoother areas with coarser elements, optimizing computational resources without sacrificing precision. Our approach also preserves original boundaries, ensuring the fidelity of simulation results. These advancements, validated through real-world examples, significantly enhance the design capabilities and modeling performance of ANSYS FORMING in stamping simulations.

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Xiaolong He
Ansys

October 23, 2024 09:45 am

Updates on trimmed IGA B-Spline Solids

IGA I

Recently, so-called trimmed Isogeometric B-Spline Solid elements have been introduced in LS-DYNA [1]. The numerical analysis methodology Isogeometric Analysis (IGA) dates to the paper by Hughes et al. [2] in 2005. While standard Finite Element Analysis (FEA) usually uses polynomial-based basis functions, IGA tends to use the same shape functions employed in the Computer Aided Design (CAD) environment for numerical analysis. This paper recalls the main ideas and concepts of the trimmed IGA B-spline solid finite elements in LS-DYNA and gives an update on the available capabilities. The current workflow of how to setup LS-DYNA models with these new types of elements will be introduced. Available methods of how to deal with boundary conditions, contact, connection modeling and refinement strategies will be shown, and some recommendations and best practices will be shared. A set of numerical studies will demonstrate the potential benefits of these new types of solid finite elements. The paper closes with a summary and an outlook of future development activities.   2 References  [1]  Hartmann, S., Leidinger, L., Bauer, F., Benson, D., Nagy, A., Li, L., Pigazzini, M., Nguyen, L.: "Trimmed IGA B-Spline Solids vs. Standard Tetrahedra Finite Elements", 14th European LS-DYNA Conference 2023, Baden-Baden, Germany. [2]  Hughes, T.J.R., Cottrell, J.A., Bazilevs, Y.: "Isogeometric Analysis: CAD, finite elements, NURBS, exact geometry, and mesh refinement", Computer Methods in Applied Mechanics and Engineering, Vol. 194, 2005, 4135-4195.

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Stefan Hartmann
Dynamore GmbH, an Ansys Company

October 23, 2024 09:45 am

Data preparation for the Euro NCAP far-side ISO18571 rating calculation with tools from the DYNAmore Eco System

Occupant/Pedestrian Safety II

In 2024 the Euro NCAP Virtual Testing far-side protocol was introduced with a monitoring phase. The protocol defines all the requirements in precise detail. To obtain an assessment for the virtual testing, the OEM needs to pass two validation load cases. The assessment is conducted using ISO18571 ratings. Euro NCAP is responsible for the ISO18571 rating calculations. The OEM must provide the simulation and test data in a predefined ISO-MME data format. If the ratings meet the defined criterion, the virtual testing assessment is deemed successful. This paper presents a straightforward workflow for preparing ISO-MME data, illustrated by a case study of a far-side test involving the open-source Yaris car and the DYNAmore WorldSID dummy model in LS-DYNA. The DYNAmore Eco System tool DM.binout2isomme is used to create the required ISO-MME files for sharing with Euro NCAP. Furthermore, the ISO18571 scores are calculated with the assistance of a Python script provided by Euro NCAP.

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Alexander Schif
DYNAmore GmbH, An Ansys Company

October 23, 2024 10:10 am

Break

October 23, 2024 10:30 am

Determination of MAT224 Fracture Surface Points for Material Subjected to Three-Dimensional State of stress

Aerospace Structure Impact & Dynamics II

LS-DYNA MAT224 is a tabulated material plasticity and fracture model. The plasticity part of the model can include strain rate, strain hardening and temperature effects. The fracture part uses a fracture surface that gives the value of the equivalent strain at fracture as a function of the state of stress (triaxiality and the Lode parameter). The fracture surface is made up of experimental data points. Each point corresponds to a specific combination of triaxiality and Lode parameter values. The value of the equivalent plastic strain at a point is obtained from an experiment in which the specimen is subjected to loads that generate the desired state of stress. Ideally, the specimen is loaded proportionally until it fractures and the value of the equivalent plastic strain at the fracture location is entered as a point in the fracture surface. When the model was first introduced the data points used for the construction of the fracture surface were obtained from relatively simple experiments like uniaxial tension tests, tension of notched flat and round specimens, pure shear, uniaxial compression, combined tension or compression with shear, and punch tests. The fracture data points from these experiments cover only a small portion of the fracture surface. In many applications fracture occurs when the material is loaded with combination of stresses that are not near the data points from the simple tests. One example is impact events associated with failure of jet engine rotating parts that impact containment and shielding systems where the penetration of debris involves plastic deformation and fracture under a three-dimensional state of stress. The present paper introduces new experiments that have been developed recently to support the MAT224 model by providing data points to the fracture surface at combinations of stresses (combinations of triaxiality and Lode parameter values) that are important in simulations of projectile impact and penetration. These stress states include biaxial equal and unequal in-plane tension and out-of-plane compression and plane strain compression. The new experiments consist of spherical and elliptical miniature punch tests of a thin specimen plate supported by a backup plate and compression of a notched ring. Digital Image Correlation (DIC) is used in all the tests to measure deformations. Numerical simulations of the tests are performed using an assumed plasticity model, and the model stress prediction is validated by matching the simulated force-displacement response and strain with the experiments.

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Amos Gilat
Ohio State University

October 23, 2024 10:30 am

Simulation of drug effects on whole heart contractility

Biomedical/Healthcare II

The human heart beats as a result of certain multiscale electro-mechanical mechanisms, ranging from subcellular to whole organ processes. Computational modelling and simulation (i.e. in-silico) studies have significantly assisted in advancing cardiac science over the last two decades. These studies permit a thorough understanding of patho-physiological mechanisms which usually involve smaller scales than those observed in a clinical setting. 

Electro-mechanical whole heart models usually consist of four different subcomponents: tissue electrical diffusion (I), tissue mechanical deformation (II), cellular electrophysiology (also called action potential models) (III), and cellular active contraction models (IV). Both I and II subcomponents act at the macroscale, and involve a set of bidirectionally coupled PDEs. III and IV act at the cellular level (or at the microscale), and involve two separate, i.e. not strongly/directly coupled, systems of ODEs. I and III are coupled via a reaction term, leading to a reaction-diffusion system of PDEs called either monodomain or bidomain equations. II and IV are usually coupled viaan active stress component.

As previously mentioned, whole heart cardiac simulations comprise of electrophyisiological and contractile cellular subcomponents which are not strongly coupled, and thus the effect of a strong electromechanical coupling at the cellular level on the whole heart has not been quantified yet. In this study, the action potential and active contraction coupling model of Margara et al. 2021 has been implemented in LSDYNA, and used in full heart electromechanical simulations. Simulations were then conducted using these models to quantify how does this strong electromechanical coupling affect key mechanical biomarkers: ejection fraction and end-systolic pressure. These were evaluated under healthy and drug exposed conditions. Drug effects were incorporated in the model by using IC50 and Hill coefficient data, as done in Passini et al. 2017, by means of simple poreblock models of drug action.

This study is, up to the authors’ knowledge, the first attempt at including a strongly coupled electromechanical cellular subcomponent in a whole heart simulation, and also at evaluating its behaviour under drug effects. The proposed simulation framework also offers the opportunity to extend whole heart simulations by including disease effects, which might be incorporated via other mechanisms, such as increased tissue mechanical stiffness and/or severely reduced tissue electrical diffusion.

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Francesc Levrero Florencio
Ansys

October 23, 2024 10:30 am

Simulation of hammer impact during driving process of offshore monopile foundation for wind energy structures

Drop/Impact Dynamics II

October 23, 2024 10:30 am

Evaluation of Viscoelastic Material Models in LS-DYNA based on Stress Relaxation Data

Material & Constitutive Modelling II

Viscoelastic behavior of a material is often used as a probe in the field of material science since it is sensitive to the material’s chemistry and microstructure. The behavior enables understanding of the quantity of energy absorbed by the material’s internal structure and the energy dissipated to the surroundings. The viscoelastic properties can be determined experimentally by tests such as stress relaxation, creep, or Dynamic Mechanical Analysis (DMA). Numerical modelling of rubber-like viscoelastic materials in terms of energy dissipation and energy storage is usually done using hyperelastic and viscoelastic constitutive models. Hyperelastic material model captures the material’s nonlinear elastic behavior with no time dependence. Viscoelastic model describes the material response as a function of time, frequency, and temperature, and contains an elastic and viscous part. This paper presents the dynamic characterization of rubber in terms of hyperelastic and viscoelastic constitutive models. The parameters of the constitutive models are determined from the uniaxial tensile and stress relaxation tests. These parameters are used for the numerical model of the rubber components and the accuracy of the characterization is presented by means of a numerical case study. Capabilities of different constitutive models available in LS-DYNA to predict viscoelastic behavior of rubbers viz., MAT76 (general viscoelastic), MAT77H (hyperelastic rubber) and MAT77O (Ogden rubber) are compared. Additionally, the recent developments under *MAT_ADD_INELASTICITY are discussed and recommendations are made for the usage of these models based on the material application.

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Vesna Savic
GM

October 23, 2024 10:30 am

Recent development in Ansys LS-DYNA's NVH solvers

NVH/Implicit 

LS-DYNA has been used by many automotive companies for many years, especially in the vehicle crashworthiness and occupant safety analysis areas. LS-DYNA also provides many useful features to help users to run NVH (Noise, Vibration and Harshness) analysis. During the past two years, numerous updates and enhancements have been made in the NVH solvers based on customers’ feedback and suggestions, including 1) A fast FRF analysis with reduced eigenvectors; 2) Frequency dependent adaptive remeshing for BEM acoustics; 3) Frequency interpolation for BEM acoustic solvers; 4) Fluid added mass computation and its application in modal and vibration analysis; 5) Coupling of acoustic spectral element method and piezoelectric material for ultrasonic sensors simulation; 6) Enhanced d3max output; and 7) New options and output in fatigue solvers. This paper aims at giving a brief introduction of these updates and enhancements to LS-DYNA users. Some examples are included in the paper for illustration purpose.

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Yun Huang
Ansys

October 23, 2024 10:30 am

Acceleration of Implicit LS-DYNA

Simulation Misc. I

Ansys has a four-decade history of using accelerators to speed up Computer-Aided Engineering (CAE).  The MAPDL Mechanical CAE code has been using Graphics Processing Units (GPUs) to accelerate implicit analyses since 2010. Following their lead, Ansys developers are now adding GPU acceleration to the linear and eigenvalue solvers in LS-DYNA. Meanwhile, the end of Dennard scaling, and arguably Moore's Law, has led to a proliferation of other accelerators, often designed to solve problems in Machine Learning and Artificial Intelligence. Ansys developers are also examining the feasibility of using some of these new devices as accelerators. In particular, we are looking to accelerate iterative linear solvers and NP-complete optimization problems. For memory bandwidth bound iterative solvers we are considering Xilinix Field Programmable Gate Arrays (FPGAs) and the Cerebras Wafer Scale Engine. For optimization, we are considering adiabatic quantum annealing with D-Wave and Pasqal, gate-model quantum computing with IBM, the digital annealers produced by Fujitsu and Toshiba, and LightSolver's optical system. Together with the vendors of the novel accelerators, we are doing this work in collaboration with UCLA, NETL, and BMW.

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Robert Lucas
Ansys

October 23, 2024 10:55 am

Application of the MAT 213 Composite Impact Model to NASA Problems of Interest

Aerospace Structure Impact & Dynamics II

A material model has been developed which incorporates several key capabilities which have been identified as lacking in currently available composite impact models.  The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength).  The material model has been implemented into LS-DYNA® as MAT 213.  The model can simulate the nonlinear deformation, damage and failure that takes place in a composite under dynamic loading conditions.  The deformation model utilizes an orthotropic plasticity formulation.  For the damage model, the nonlinear unloading response that is observed prior to the point where the peak stress is reached can be simulated, as well as the stress degradation response that occurs after the peak stress is reached.  A variety of failure models, including a generalized tabulated failure model which facilitates the utilization of general failure surfaces, have been implemented into MAT 213.  Recent studies at NASA have concentrated on using MAT 213 to analyze both the impact and crush response of a variety of laminated and textile architectures.  Several of these studies will be discussed in the presented paper.  For example, a woven carbon/Kevlar composite is currently being examined for use in an energy absorber system for rotorcraft structures.  MAT 213 analyses have been conducted to examine the ability of the model to accurately simulate the dynamic crush response of this material.  Studies are also being conducted to examine the ability of MAT 213 to simulate the ballistic impact response of representative laminated and woven thermoplastic and thermoset matrix composites.  NASA efforts are also concentrated on developing methods and processes for improving characterization methods and developing  “best practices” for using MAT 213, a summary of which will be discussed in the paper.

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Robert Goldberg
NASA Glenn Research Center

October 23, 2024 10:55 am

A New Eikonal Solver for Cardiac Electrophysiology in LS-DYNA

Biomedical/Healthcare II

Heart disease is among the leading causes of death in the Western world; hence, a deeper understanding of cardiac functioning will provide important insights for engineers and clinicians in treating cardiac pathologies. In this paper we will concentrate on the electrophysiology (EP) part of the physics, which describes the propagation of the cell transmembrane potential in the heart. In LS-DYNA, EP can be coupled with the mechanics and the fluid solvers for a Multiphysics simulation of the heart, but pure EP is also often used to investigate complex phenomena such as cardiac arrhythmias or fibrillations.  The gold standard model for EP is the “bi-domain” model, along with the slightly simplified “mono-domain”. These were introduced in LS-DYNA a few years ago. They give very accurate predictions, but the associated computational expenses are significant, which can be an issue for patient-specific predictions, for example, cardiac activation patterns for complex procedures such as cardiac resynchronization therapy (CRT). In this paper we introduce new computationally efficient eikonal and reaction-eikonal solvers. The eikonal method is very general and describes the propagation of a wavefront in a medium with given propagation velocities. The solution is the arrival time of the wave at each node, which corresponds to the activation time in the case of EP. This activation time can either be used to just trigger an action potential at each node independently, or a spatial diffusion term between nodes can also be added so that each node can influence its neighbors. The eikonal solver works on the 3D elements of the myocardium, but also on the beams composing the rest of the conduction system of the ventricles, i.e. the bundle of His, the left and right bundle branches, and the Purkinje network, which can all be coupled. Also, the eikonal solver can handle several waves by tracking more than one activation time per node. This allows for example to simulate reentry phenomena.   The eikonal solver will be presented and different examples will be shown.

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Pierre L'Eplattenier
Ansys

October 23, 2024 10:55 am

Advancing Solder Joint Modeling in PCBs: A Two-Scale Co-Simulation Approach for Shock & Vibration Analysis Using LS-DYNA

Drop/Impact Dynamics II

The integrity of solder joints in PCBs under dynamic loading conditions is critical for the reliability of electronic devices. Traditional modeling methods, such as representing solder joints with beam elements or solid elements in one-scale simulations, often face trade-offs between computational efficiency and accuracy. In this study, we introduce a two-scale co-simulation approach using LS-DYNA to address this challenge and provide both accuracy and efficiency in PCB analysis.  Conventionally, one-scale methods either sacrifice accuracy for computational speed by using beam elements or prioritize accuracy at the cost of computational efficiency through solid element modeling. However, our proposed two-scale approach strikes a balance between these two factors. By dividing the model into a global component representing the entire PCB assembly and a local component focusing solely on detailed solder joint modeling, computational resources can be optimized effectively.  A key advantage of the two-scale method lies in its two-way information exchange between the local and global models. Unlike traditional submodeling techniques, where information flow is typically one-way, our approach enables comprehensive communication between the global and local scales at each time step. This bidirectional exchange ensures that the effects of local solder joint behavior are accurately integrated into the global analysis, leading to improved accuracy compared to traditional one-scale methods.  To evaluate the effectiveness of the two-scale approach, we conducted a comparative analysis with one-scale simulations. Our results demonstrate that the two-scale method achieves superior accuracy, with an error rate of only 10% compared to the benchmark. Furthermore, the two-scale approach offers significant computational savings, reducing the running time by approximately 40% compared to one-scale methods. By accurately capturing the intricate dynamics of solder joints within the broader context of PCB assembly, our approach provides engineers with a reliable tool for optimizing the reliability and performance of electronic devices.  In summary, this study presents a novel two-scale co-simulation approach for shock and vibration analysis of PCBs, offering a balanced solution that combines accuracy and efficiency. By leveraging the advantages of both global and local modeling, our methodology represents a significant advancement in the field of PCB analysis.  Keywords: PCBs, Solder Joints, Shock and Vibration Analysis, Finite Element Analysis (FEA), Two-Scale Co-Simulation, Computational Efficiency.

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Henan Mao
ANSYS INC

October 23, 2024 10:55 am

A Physically based strength prediction model for glass

October 23, 2024 10:55 am

Advancements in Eigenvalue Technology

NVH/Implicit

We will provide a overview of our work to improve the Lanczos, Fast Lanczos, and LOBPCG eigensolvers in LS-DYNA, especially focusing on the performance on large automotive models. We will describe our efforts of providing new technology for problems with additional physics such as rotational dynamics and the mixed-up formulation.

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Francois-Henry Rouet
Ansys

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Daniel Bielich
Ansys

October 23, 2024 10:55 am

Efficient High-Performance Compute for Ansys LS-Dyna Leveraging NVIDIA Grace Platform

Simulation Misc. I

The NVIDIA Grace CPU, based on the ARM Neoverse V2 architecture, presents a significant advancement in High Performance Computing (HPC) through its focus on power efficiency and performance. The CPU is packaged as a "superchip," comprising of two 72 core Grace CPUs interconnected by a 900GB/s chip to chip link. This configuration is further supported by up to 960GB of LPDDR5X memory, which offers high bandwidth and low power consumption. The architectural improvements and memory integration enable the Grace CPU to achieve higher computational efficiency compared to alternative CPU designs.  Performance assessments using Ansys LS-Dyna simulations were conducted on both single-node and multi-node Grace Superchip systems. The results demonstrate that the Grace CPU platform provides comparable computational performance to existing HPC platforms, with the added benefit of improved power efficiency. These findings suggest that the Grace CPU is a new option for HPC applications like Ansys LS-Dyna, offering performance and energy efficiency.

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Ian Pegler
NVIDIA

October 23, 2024 11:20 am

Simulation-Aided Design of Compression Specimens for Accessing New States of Stress During Ductile Fracture

Aerospace Structure Impact and Dynamics II

In gas turbine engine blade-release or rotor-burst events, the impact and subsequent penetration of high-speed engine fragments with the engine case or aircraft structure are notoriously difficult to model and simulate.  A key ingredient in many state-of-the-art ductile fracture models is the failure locus, a three-dimensional surface plot of the equivalent plastic strain at fracture as a function of the state of stress, as quantified by the stress triaxiality and Lode parameter.  Generally, the failure locus is calibrated using standard mechanical tests.  However, these standard tests are only able to capture a limited window of stress states.  In this talk, to enable new states of stress at fracture, we present novel design permutations of recently proposed compression specimens with through holes and spherical recesses, as well as a combined compression-torsion specimen.  The geometry and arrangement of these through holes and spherical recesses provide a broad array of design permutations, while the combined loading allows for tailoring of different amounts of torsion and compression.  Preliminary simulations indicate compelling potential to add new ductile fracture data to the underpopulated positive (compressive) triaxiality region of the failure locus for aerospace metals.  The outcomes from this effort are expected to enhance the fidelity of predictive models used by the Federal Aviation Administration (FAA) Aircraft Catastrophic Failure Prevention Program and aircraft OEMs to simulate the impact physics of blade-off and rotor-burst events.

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Ethan White
University of Dayton

October 23, 2024 11:20 am

Pyheart-lib: A Python Library For LS-DYNA Multi-Physics Heart Simulations

Biomedical/Healthcare II

October 23, 2024 11:20 am

Combining Physical Test with Structural Explicit FEA to Develop Package-Specific Failure Models for Electronic Components

Drop/Impact Dynamics II

Electronics use in vehicles has increased significantly over the past few decades and accounts for 40% of a new car's cost today.  Automotive electronic assemblies see high shock/vibration environments with mechanical shock experienced in a variety of scenarios such as a door slam, a vehicle crash or going over a pothole. The solder joints that connect the electronic components to their circuit boards are common failure locations in electronic assemblies, particularly in high shock/vibration environments and extreme power cycling conditions The failure behavior for a particular component's solder joints is heavily influenced by the component's package construction and materials.   Automotive qualification testing, which is required to ensure that component/system design meets verification and validation requirements with respect to performance and manufacturing, can be expensive and time consuming.  Using a finite element approach, component-level failure models can be used in conjunction with simulation to predict load-specific failure and virtually test designs to gain confidence ahead of physical qualification testing.  Ball grid array (BGA) packages, in mechanical shock and thermal cycling environments are common in automotive environments and were the focus of this workflow. The goal was to create both failure models and FEA strategies using a simplified test board that can then be used going forward whenever the electronic component is used in a real product design.  This presentation will outline how to create and validate simulation-based, component-specific failure models by correlating FEA to physical test. The component-level failure prediction approach is then extended to assess the reliability of these components when incorporated into larger assemblies. LS Dyna was used to solve FEA models in an Ansys workbench environment, using material properties derived from analysis and measurement of the components of interest.  Drop testing was conducted to tune and validate FEA model behavior at various stress levels and build confidence in the modeling approach.

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Mike Howard
Ansys, inc.

October 23, 2024 11:20 am

Considering the Local Anisotropy in the Simulation Process Chain for Short and Long Fiber Reinforced Thermoplastics

Material & Constitutive Modelling II

A huge number of short and long fiber reinforced thermoplastics play a decisive role in the automotive industry to ensure affordable lightweight design and availability in large quantities. The properties of these materials are especially highly influenced through the manufacturing process (typically injection molding for SFRT and LFRT). Over the last years, there is a strong industry interest to consider the manufacturing process induced local anisotropy inherent in these materials under a crash scenario. This paper is a collaborative work undertaken with our partner Dr. Ing. h. c. F. Porsche AG that deals with the material testing with IMPETUS® and the material modelling calibration process for a *MAT_4A_MICROMEC with VALIMAT® in LS-DYNA. Besides the validation of anisotropic material deformation behavior, the calibration of the failure behavior is also considered in extensive detail. To obtain such a high-quality material card a workflow is developed, starting with molding adequate plaques for test specimens to characterize the underlying deformation and failure behavior at the coupon level under different loading scenarios up to final validation on component level.

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Harish Pothukuchi
4a engineering GmbH

October 23, 2024 11:20 am

The new linear solver with nonlinear contacts

NVH/Implicit

October 23, 2024 11:20 am

Application of ISPG Method in Various Manufacturing Processes Simulation

Simulation Misc. I

Application of ISPG Method in Various Manufacturing Processes Simulation Li Zhang, Xiaofei Pan, Michael Su, Jingxiao Xu, C.T. Wu Incompressible Smooth Particle Galerkin (ISPG) theory was first proposed by the R&D team CMMG at LSTC back in 2017. It developed a new Incompressible Navier-Stokes solver for modeling of free-surface Newtonian and Non-Newtonian fluid flow with surface tension and adhesion force. The Lagrangian particle method was employed to discretize the ISPG part to approximate the Navier-Stokes equation, which is strongly coupling with surrounding rigid structures. ISPG method is fully implicit, and in its dynamic mode, it simulates in real time fluid behaviors in many applications. ISPG’s robust, in-core, and smart mesh adaptivity allows fluid flow in complex geometry, accurately capture and align the ISPG surfaces with the structure surfaces, while keeping the model size down. It also allows for ISPG part separation and fusion. The ISPG advanced material models allows for simulation of fluid behavior with various viscosity from water to near solid state. ISPG technology was first applied in solder reflow simulation back in 2019. Since then, with more features and improvement to the code, it found itself in many other interesting areas of applications. In this paper, we will focus on showcasing the various applications of the ISPG method spanning many industries, including, but not limited to, compression molding, adhesive flow; and in semiconductor manufacturing area, PCB solder paste printing and stencil removal, capillary flow (underfilling) of the PCB. The latter two are integral part of the Chip manufacturing process along with the solder reflow. We will also discuss the limitations of the method in its current state.

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Li Zhang
Ansys, Inc.

October 23, 2024 11:45 am

Development of Anisotropic Plasticity Model of Titanium-6Al-4V for *MAT_264 for Ballistic Impact Simulations

Aerospace Structure Impact and Dynamics II 

October 23, 2024 11:45 am

Simulation of Oldroyd-B viscoelastic liquid jets with LS-DYNA ICFD

Biomedical/Healthcare II

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Zlatko Solomenko
Ansys

October 23, 2024 11:45 am

Fast Study of Multiple Sizes Helmets and Design Shape Optimization using LS-DYNA, LS-OPT and DEP MeshWorks

Drop/Impact Dynamics II

October 23, 2024 11:45 am

Modelling of failure in aluminium high-pressure die castings

Material & Constitutive Modeling II

Aluminium high-pressure die castings (HDPC) are becoming more and more relevant parts in the automotive sector. This type of parts offers a high flexibility in terms of design which has been used to reduce significantly the number of parts in a car body and potentially save weight compared to traditionnal steel components. On the negative side, aluminium HPDC parts generally suffers from a low ductility (for non-heatred alloys) and considerable variations in failure strains. Designing such parts to sustain severe mechanical loadings is thus challenging since material variations can lead to catastrophic failure. To account for the stochastic character of aluminium HDPC materials, a large number of simulations, where the failure properties are varied in a random manner, should be carried out to capture the potential span of responses of the structure at hand. This procedure is however difficult to use in practice due to the potential large number of simulations to be carried out and analysed. In this work we will present an alternative approach where a single simulation is carried out and the probabilities of failure are computed a posteriori within a python environment. We will cover the aspects of calibration, its mathematical foundation and application of this method. Using this method we will discuss the stress-state dependency of the ductility of an aluminium HDPC alloy. Finally, we will demonstrate the applicability of this technique on a laboratory scale HDPC part.

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David Morin
Norwegian University of Science and Technology

October 23, 2024 11:45 am

Introduction of LS-DYNA MCOL solver coupling with Ansys Aqwa for the application in shipbuilding analysis

NVH/Implicit

October 23, 2024 11:45 am

LS-DYNA Smoothed Particle Galerkin (SPG) method for ductile failure simulation: feature updates, development road map

Simulation Misc. I

CAE society faces a significant challenge in simulating dynamic deconstructive processing in 3D ductile or quasi-brittle solids such as metal, concrete, bone, wood, etc. Ansys researchers developed the LS-DYNA Smoothed Particle Galerkin (SPG) method for these types of application. Unlike other mesh-free methods, SPG uses direct nodal integration (DNI) without background mesh and a novel bond failure mechanism to predict the material failure behavior. The manufacturing processing such as drilling, grinding, and piercing usually involves large plastic deformation and complex sample/tool contact conditions. To address these technical demands, LS-DYNA developers released new features such as new contact algorithms which are compatible with particle/surface interactions, various damage models for different failure patterns. For the upcoming development road map, SPG developers focus on efficiency improvement with algorithm updates and heterogeneous computational platform: CPU/GPU hybrid calculations.

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Bo Ren
Ansys

October 23, 2024 12:10 pm

Lunch

October 23, 2024 01:15 pm

Experimental Calibration of Flow Rule Coefficients for LS-DYNA MAT_213

Aerospace Structure Impact and Dynamics III

Composite materials have become popular choices in aerospace engineering applications due to their low weight, high specific stiffness, high specific energy absorption, and more. As use of composite materials has proliferated, the need for accurate simulation under extreme loading conditions is of increasing importance. *MAT_213 is a tabulated plasticity and damage material model in LS-DYNA designed for such use cases. To account for the nonlinear material response, a plasticity algorithm is used which employs a non-associative flow rule. The coefficients of this non-associative flow rule require calibration for the user’s material of interest. This work outlines a methodology for calibrating these coefficients using data from coupon scale experiments. The model material used for development and demonstration of this methodology is a plain-woven fabric with T300 carbon fiber tows in the warp direction and Kevlar© 49 fiber tows in the weft direction. This fabric is encased in an Epon© 828/Epikure© 8552 thermoset epoxy matrix. Coupon-scale tensile testing performed at multiple fiber angles (carbon fibers oriented 0º, 22.5º, 45º, 67.5º, and 90º relative to loading axis) provides data for multiple calibration processes. The first is finding ratios between flow rule coefficients that result in the convergence of different coupon responses in the effective stress – effective plastic strain space. This is done in a similar albeit slightly more general fashion than previous works [1-3]. Additionally, transverse and axial strain responses for various fiber angles allow for the use of plastic Poisson’s ratio in global coordinates as an initial estimate for ratios of the flow rule coefficients. Flow rule coefficients found by this methodology are then used as input for LS-DYNA simulations of uniaxial tension, compression, and Iosipescu shear coupon tests at varying fiber angles. These results are quantitatively and qualitatively compared to macroscopic stress-strain curves and spatial distribution of experimentally measured strain maps within the tested configuration gauges. The conformity of the experimentally measured quantities with those derived from the simulations provide a means for assessing the quality of calibrated coefficients.

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Daniel Slaughter

October 23, 2024 01:15 pm

Adaptive FEM-DEM simulation of a soft missile impact on a reinforced concrete slab

Blast/Impact Dynamics

Introduction Modeling the behavior of reinforced concrete (RC) structures under the action of destructive loads, considering the non-linear material properties and the strain-rate effects, are prescribed according to the requirements of The International Atomic Energy Agency (IAEA) in the design of buildings and structures of Nuclear Power Plants (NPP) [1].  A soft impact of a body imitating an aircraft engine missile is considered according to experiments [2]. Such a study can determine the ability of RC structures to withstand the impact of an engine or other large aircraft fragment. The paper describes an approach to solving such a problem, especially for a large-thickness under-reinforced slab made of low-quality concrete. Such a combination of design parameters may prove challenging for FE modeling due to significant mesh distortions and the need to model material erosion.  Model and Methods Modeling a soft impact on an under-reinforced slab of low-strength concrete is a challenging computational problem for traditional mesh methods. The structure's stiffness is not correctly represented when a coarse FE mesh is used. If a fine FE mesh is used, the calculation is unstable due to large deformations of the elements. Requires element erosion techniques to be involved. However, this may cause the formation of internal voids in the structure and, therefore, will not allow it to comply with the laws of conservation of mass and momentum. In addition, there is a danger of using the criterion of element removal artificially introduced into the material model as a fitting parameter, which allows for achieving agreement with the experiment but does not give a physically correct solution.  The possibility of converting eroded mesh elements into discrete elements built into LS-DYNA is considered in the paper. The approach allows us to improve accuracy with the preservation laws and clarify the mechanics of structural failure. Thus, the solver can improve the demolished concrete behavior simulation and account for the fragments' interaction with the reinforcement cage, which is not available when converting elements to SPH particles [3].  Concrete material modeling is performed using the CSCM material model. In the standard version, this model is suitable for calculations of concrete with an unconfined axial strength of 34 – 45 MPa. However, the authors have developed and published a methodology that extends this range up to 20 – 60 MPa [4].  Summary The described technique provides one of the solutions to the problem of conservation of the laws of mass and momentum when erosion of elements is included in the issue of destructive loading of reinforced concrete structures. The calculations show good agreement with the experiment.  Literature [1] Novozhilov, Y., et al., "Aircraft NPP Impact Simulation Methodology" 16-th International LS-DYNA Conference, 2020, https://www.dynalook.com/conferences/16th-international-ls-dyna-conference/simulation-t9-2/t9-2-e-simulation-096.pdf/view [2] Sugano, T. et al., "Local damage to reinforced concrete structures caused by impact of aircraft engine missiles Part 2. Evaluation of test results," Nuclear Engineering and Design, Volume 140, Issue 3, 1993, Pages 407-423, ISSN 0029-5493, https://doi.org/10.1016/0029-5493(93)90121-O [3] Dmitriev, A., et al., "Simulation of Concrete Plate Perforation by Coupled Finite Element and Smooth Particle Hydrodynamics Methods," Construction of Unique Buildings and Structures, 92(9207) 2020, https://doi.org/10.18720/CUBS.92.7 [4] Novozhilov, Y., et al., "Precise Calibration of the Continuous Surface Cap Model for Concrete Simulation. Buildings," Buildings, Volume 12, Issue 4, https://doi.org/10.3390/buildings12050636

October 23, 2024 01:15 pm

Simulation of sheet metal forming using solid elements

Forming III

speaker headshot

Xinhai Zhu
Ansys

October 23, 2024 01:15 pm

Pre-processing IGA models with ANSA

IGA II

October 23, 2024 01:15 pm

Virtual Testing Protocols and LS-DYNA Pre and Post Processing Solutions in the Oasys LS-DYNA Environment

Pre and Post Processing

speaker headshot

Alasdair Parkes
Oasys LS-DYNA Environment

October 23, 2024 01:15 pm

LS-DYNA User-Defined Internal Ballistic Modeling

Simulation Misc. II

speaker headshot

Sirri Oguz
NASA

October 23, 2024 01:40 pm

Failure Analysis of Adhesive Joints for Composites

Aerospace Structure Impact and Dynamics III

speaker headshot

Christopher Sorini
Southwest Research Institute (SwRI)

October 23, 2024 01:40 pm

A new set of Eulerian Solver inside LS-DYNA

Blast / Impact Dynamics

speaker headshot

Hayley Easter
Ansys

October 23, 2024 01:40 pm

Trimline Development Application with Ansys Forming

Forming III

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Jeanne He

October 23, 2024 01:40 pm

CAD-integrated Untrimmed Body-fit Unstructured Spline LS-DYNA Preprocessing for Isogeometric Analysis and Digital Twins

IGA II

Isogeometric Analysis (IGA) has emerged as a next generation advancement in the field of Computer-Aided Engineering (CAE) and simulation thanks to its ability to utilize geometric representations native to Computer-Aided Design (CAD) models. LS-DYNA's proven capabilities for IGA has made it the premier solver for the technology. While the direct benefits for analysis are well documented, industrial adoption has been hampered by the difficulty in producing IGA-ready models from CAD data. Trimmed multi-patch IGA preprocessing approaches have seen advances at the industrial level but the desire for untrimmed body-fit unstructured splines has remained an unsolved approach in IGA preprocessing. In this paper, we discuss an IGA preprocessor for LS-DYNA that not only produces untrimmed body-fit unstructured splines but does so in a process that is integrated directly into a CAD application. This allows for a direct coupling between CAD and IGA alleviating the intersections between surfaces in the native CAD model consisting of approximations represented by curves rather than explicit surface-to-surface continuity, resulting in what is referred to as a “geometrically non-watertight” model. nVariate& technology creates a watertight spline CAD model in such a way that the intersections between surfaces are defined without gaps. We are able to retain all of the product and manufacturing information (PMI) associated with the original CAD model as well as provide a two-way link to the original design model. In addition, our unique watertight technology allows for model integration and a direct link to CAE from currently disparate domains such as Computer-Aided Inspection (CAI) and Computer-Aided Manufacturing (CAM). We show that not only is there a utility for IGA preprocessing in providing a CAD-integrated untrimmed body-fit unstructured spline technology for LS-DYNA but beyond preprocessing there are benefits for the synchronization of data across the digital thread in providing a representation for digital twins.

October 23, 2024 01:40 pm

Ensuring conformity and high level productivity between ANSA and LS-DYNA during model and load case development

Pre and Post Processing

October 23, 2024 01:40 pm

Spotweld Modeling Methodologies and Failure Characterization of Aluminum Resistance Spotwelds (RSW) using LS-DYNA

Simulation Misc. II

Robust joints in automotive body structure play vital role in structural performance during crash event. With increased use of Aluminum in vehicles, deep understanding of failure modeling of Aluminum Resistance Spotwelds is critical. This paper discusses failure card development of aluminum RSWs using LS-DYNA for certain 5xxx & 6xxx alloys used in structural applications. Detailed study and comparison of various material models was conducted, and appropriate model was chosen to effectively achieve project objective.    Several CAE sensitivity studies of failure parameters, weld modeling techniques, weld element orientation, parent material mesh size, tied contacts and heat affected zone were conducted. Findings were insightful and helped to select preferred modeling approach.      Various methods in failure model to improve axial loading prediction were evaluated and compared. Eventually, recommendations have been made to use appropriate keywords. Numerous simulations were run to study ‘post-failure damage’ modeling using *Mat_100_DA model. Results concluded to very interesting findings which indicated what care should be taken while using damage and using hex clusters.    For instance, it was found that the UNIAXIAL option might not fulfill its promises when the plates joined have different stiffness and a hex cluster is used. The hex cluster must be in a uniaxial stress state for the plastic strain to grow as expected. Two plates with different stiffness put certain elements of hex cluster in a mixed stress state. Local deformation in the plates generates shear stress components in hex cluster; if stiffnesses are different. The behavior during damage depends on how fast the hex cluster will reach (or not reach at all) a uniaxial tension stress state.   This paper examines the efficacy of different testing methods including flat coupon testing (Lap shear, Cross tension, and Coach peel) and KS-2 testing. The paper also elaborates types of tests conducted to develop failure cards and shows test to CAE correlation.    Overall, this paper delves into the failure modelling possibilities of a resistance spot welding for aluminum sheets, elucidating the impact of each variable involved in the modelling process. It also demonstrates comparison with physical test data and gives recommendations on preferred modeling approach.

speaker headshot

AKSHAY KULKARNI
Novelis

October 23, 2024 02:05 pm

Hourglass Control Recommendations for Simulating Reinforced Concrete under Low Velocity Impact

Blast/Impact Dynamics

The performance of reinforced concrete structural components under impact loading has received significant attention over the past decade using high fidelity numerical simulations to supplement the available experimental test data.  Several studies have evaluated the prediction of impact force and displacement time histories, as well as cracking and spalling, using a number of constitutive models in LS-DYNA.  Under-integrated hexahedral elements are typically used in these analyses with hourglass control introduced to suppress hourglass modes.  Prior studies have demonstrated the sensitivity of reinforced concrete impact analysis to hourglass coefficients, but the selection of hourglass coefficients has been limited to select comparisons with experimental time history measurements.  Furthermore, studies contrasting the performance of different constitutive models have routinely used a single hourglass coefficient for all models despite each constitutive model demonstrating unique sensitivity to the hourglass control.   To provide detailed insight into the effect of hourglass control type and coefficient on the simulated response of reinforced concrete to low velocity impacts, an extensive numerical campaign was conducted using experimental data from a series of five different reinforced concrete beam specimens subjected to drop hammer loading to validate the results.  Prevailing constitutive models for dynamic analysis of reinforced concrete, including Continuous Surface Cap, Winfrith, Karagozian and Case Concrete, RHT, and Concrete Damage Plasticity, are included in the investigation to examine the sensitivity of each constitutive model to the hourglass control parameters.  The study quantifies the influence that hourglass type and coefficient have on impact force, and displacement response, and relative hourglass energy.  Furthermore, the significant effect of hourglass control on fringes of maximum principal strain, which are typically used as an indicator for location and severity of cracking in reinforced concrete, is investigated.  Recommendations for establishing parameters for hourglass control in the simulation of reinforced concrete beams under low velocity impact are formulated for each constitutive model based on the results of the study.

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Amirmohammad Samadzad
University of North Carolina at Charlotte

October 23, 2024 02:05 pm

Trim curve development in forming simulation

Forming III

In blanking and trimming operations, selecting the right trimming curves is crucial to achieve the desired geometry in the final part. However, selecting the right trim lines can be challenging, especially parts that require multiple stamping operations. State-of-the-art Finite Element (FE) simulation tools assist designers in finding the optimal trim curves, avoiding costly physical experimentation.   One alternative is to manually adjust the trim lines in the FE model until the final part meets the dimensional requirements, which is a time-consuming approach and might not yield satisfactory results. To address this, ANSYS Forming introduces a dedicated functionality that automatically searches for the optimal trim curves.   In ANSYS Forming, the trim curve development iteratively adjusts the lines used in blanking and subsequent trimming operations. The simulation ends when the boundaries of the part are within a predefined tolerance of a target geometry.   In this presentation, we will introduce some recent enhancements related to this function and provide some usage guidelines. The latest updates to the trim curve development result in a faster convergence to the desired final geometry. To illustrate best practices, we provide relevant application examples from the automotive and semiconductor industry.

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Pablo Hernandez Becerro
Ansys

October 23, 2024 02:05 pm

Computation efficiency in IGA Solid by applying subcycling technology

IGA II

October 23, 2024 02:05 pm

CAE Process Automation using ANSA and SPDRM for creating crash digital models

Pre and Post Processing

The advantages of process automation are widely known among CAE engineers: standardization of input data and work during the individual steps assuring a consistent result of a high level of quality (human error free),  drastic reduction of the CAE turnaround time by tackling complex tedious problems in an automatic repetitive way and  gives the capability to involve in the production engineers with less experience in the specialized processes.  This automation can take place on two levels. Either at the level of individual custom developed tools, which conduct complex repetitive processes, that are handled within ANSA with the automatic use of interrelated ANSA capabilities/functionality. Or in a more integrated wider environment (system), SPDRM, where the processes are more complex and extensive and where also the full automated management of the data between the various individual processes is taken over by the system.  Both cases will be explained by demonstrating corresponding examples. From the import of the CAD data and its preparation for the CAE processes, to the automated build of various subsystems of a digital crash model, to the set-up of the load case and finally to the export of the ready-to-submit files.

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ALEXANDROS KALOUDIS
BETA CAE Systems

October 23, 2024 02:05 pm

Progressive Damage and Failure Analysis for Structural Continuous Fiber Composite

Aerospace Structure Impact and Dynamics II

October 23, 2024 02:05 pm

Use of LS-DYNA for Estimating Earthquake-induced Ground Settlements

Simulation Misc. II

October 23, 2024 02:30 pm

Validating wear simulations in heat exchanger plate stamping process through comparative analysis with experimental data for enhanced productivity and quality

Forming III

Mesh adaptivity refines the blank mesh as needed in stamping simulations. Users do not need to anticipate where a dense mesh will be required. Despite its universal use, it demands significant effort due to serialization and the need to carry a dense mesh through subsequent iterations. In-Core adaptivity and Mesh fusion assist the solver in conserving effort, thereby enhancing performance. This paper will demonstrate best practices for utilizing In-Core adaptivity and Mesh fusion in Ansys Forming through practical cases. In addition, for different model, we should find an optimum number of CPUs to run the job. Beyond this number, the scalability will not see any obvious improvements.

speaker headshot

Kang Shen
Ansys

October 23, 2024 02:30 pm

Simulating Global Motion of the Brain in Response to Trauma: A Biomechanical Approach Florida Atlantic University - Wilkes Honors College

Aerospace Structure Impact and Dynamics III

October 23, 2024 02:30 pm

Overview of LS-TaSC and New Feature Highlights

Pre and Post Processing

October 23, 2024 02:30 pm

Continuum-based Particle Gas (CPG): A New Approach for Airbag Deployment Simulations

Simulation Misc. II

The evolution of automotive safety systems has witnessed a remarkable journey over the past few decades, with airbags emerging as pivotal components in mitigating the severity of injuries during vehicle collisions. Initially conceived as relatively simple passive restraint systems, airbags have undergone a profound complexification in their design and functionality, driven by the relentless pursuit of enhanced occupant protection and regulatory compliance. Today, modern vehicles incorporate a diverse array of airbags strategically positioned throughout the cabin to address various collision scenarios. From front and side airbags to curtain and knee airbags, this proliferation underscores the nuanced approach to occupant protection adopted by automotive manufacturers.  However, from a numerical analysis standpoint, this increased complexity has introduced new challenges. Modeling airbag deployment has been challenging from the outset due to the intricate dynamics of airbag inflation and the complex Fluid-Structure-Interaction (FSI) involving gas, airbag fabric, and internal components. While initial endeavors primarily aimed to accurately depict the interaction between occupants and fully inflated airbags, modern CAE tools must now also predict the entire deployment phase with exceptional precision, necessitating the incorporation of complex physics into the numerical methods. Developed two decades ago, the Corpuscular Particle Method (CPM), rooted in kinetic gas theory, quickly emerged as the preferred technique for sophisticated airbag modeling. This method adeptly handles intricate airbag designs and has demonstrated considerable utility. Nonetheless, the recent trend towards increasingly complex airbag designs, coupled with the growing need for high-fidelity resolution during initial deployment stages, has underscored certain shortcomings in effectively resolving local flow characteristics using this method. In our presentation, we introduce a novel method for simulating airbag deployment known as Continuum-based Particle Gas (CPG), which relies on continuum physics principles. Like CPM, CPG is a particle-based approach that eliminates the need for meshing the airbag & internal volume. However, CPG adopts continuum theory and resolves the compressible Navier-Stokes equation coupled with an ideal gas equation of state. Our emphasis will be on explaining the theoretical foundations of the CPG solver and showcasing numerical examples, supported by theoretical analysis or experimental findings where appropriate.

speaker headshot

Edouard Yreux
Ansys Inc

October 23, 2024 02:55 pm

Break

October 23, 2024 03:15 pm

Using Analysis for Decision Making in Aerospace Applications

General Session

speaker headshot

Joseph Pellettiere
FAA

October 23, 2024 03:40 pm

Update on LS-DYNA Developments

General Session

speaker headshot

C.T. Wu
Ansys

October 22, 2024 07:30 am

Exhibits Open

Exhibition

October 22, 2024 07:30 am

Continental Breakfast

Meals

Walk the exhibition space to grab your quick breakfast before general session.

October 22, 2024 07:30 am

Registration

Registration Desk Open

October 22, 2024 08:30 am

Engineering the Road Ahead with Simulation

General Session

As the Transportation industry evolves and innovates to deliver upon the goals of clean and safe mobility, efficient engineering processes are critical.   A key enabler in shortening and making the engineering processes more efficient is simulation. Visionary automotive companies know how their world-changing ideas will perform well before prototypes and production through the use of simulation and model-based systems engineering.  No longer relegated to CAE departments, simulation has changed tremendously over the past few years, empowering every engineer to innovate faster than ever before. Learn how the latest technologies in AI/ML, physic-based numerics and cloud services have transformed workflows to deliver the latest innovations in electrification, ADAS/AD, SDV, and vehicle attributes.

speaker headshot

Judy Curran
Ansys, Inc.

October 22, 2024 09:05 am

Pushing the Performance Limits: How Ansys powers Oracle Red Bull Racing's Competitive Edge

General Session

The use of numerical tools and virtual analysis plays a critical role in the design and optimization of Formula 1 cars.  To deliver race-winning performance on the track, Oracle Red Bull Racing relies on virtualized design and development to reproduce real-world scenarios and re-create the complex physical environment off the track. This continuous and rapid process ensures the car is optimized for maximum performance at each racetrack. 

Gennaro will highlight how Oracle Red Bull Racing leverages Ansys technologies for aerodynamic development and thermal management to the virtual testing of impact structures. Through the accuracy and fidelity in reproducing virtual testing environments, Ansys enables the Team to reduce costs and time necessary for physical prototypes, enabling quicker iterations and innovations in the fast-paced world of Formula 1. The Innovation Partnership with Ansys is crucial for Oracle Red Bull Racing to maintain the competitive edge in Formula 1 and to deliver exceptional performance on and off the track. 

speaker headshot

Gennaro Serino
Oracle Red Bull Racing

October 22, 2024 09:40 am

Safety Simulation Enhancement Using AI

General Session

speaker headshot

Rajkumar Rajagopalan
STELLANTIS

October 22, 2024 10:05 am

GHBMC and the Applications of GHBMC Models

General Session

speaker headshot

Chin-Hsu Lin
General Motors Research and Development Center

October 22, 2024 10:30 am

Break

Meals

October 22, 2024 10:45 am

Opening Remarks: Electrification and ADAS

Electrification and ADAS

October 22, 2024 10:45 am

Opening Remarks: Electronics and Lighting

Electronics and Lighting

October 22, 2024 10:45 am

Opening Remarks: Safety and Systems

Safety and Systems

October 22, 2024 10:45 am

Opening Remarks: Digital Engineering

Digital Engineering

October 22, 2024 11:00 am

Develop High-Efficiency Electric Vehicle Powertrains (ConceptEV)

Electrification and ADAS

Ansys ConceptEV is a new innovative cloud-based design and simulation platform for the design of EV powertrains. Engineers can collaborate on a shared system simulation connected to requirements from the start of the design process. ConceptEV provides a model-based approach to optimizing the powertrain system & components with rapid evaluation of different powertrain configurations and component design choices using innovative simulation techniques.

speaker headshot

Pavani Gottipati
Ansys

October 22, 2024 11:00 am

Driving into the Future of Software-Defined Vehicles with Ansys

Electronics and Lighting

The automotive industry is undergoing a transformative shift towards Software-Defined Vehicles (SDVs), where vehicle functionalities are increasingly driven by software. Managing the scalability, flexibility and interoperability of systems across diverse vehicle models is critical for successful deployment. This challenge involves the development of new hardware architectures and electronics as well as new software features. Ansys provides a comprehensive and integrated suite of tools and solutions that address the engineering challenges of software-defined vehicle development. Solutions for model-based system engineering, electronics design from chip to system, software development using real-time plant models and virtual validation of customer features. In this presentation, we will discuss how Ansys solutions enable OEMs and suppliers to partner to design, validate, and deliver the vision of the SDV.

speaker headshot

Domenico Caridi
Ansys

October 22, 2024 11:00 am

Ansys Journey Towards Digital Engineering

Safety and Systems

Digital Engineering is in the focus of many companies to improve their product development. It is concerned with the application of digital methods and tools covering the complete lifecycle of products, from conception through to operation and maintenance. Ansys is going to provide our customers with a digital engineering experience covering important aspects in key areas like MBSE, model-based software development, model-based compliance, and engineering simulation. In the talk our approach to Digital Engineering is discussed with a focus on safe software and compliance to safety and cybersecurity regulations.

speaker headshot

Marc Born
Ansys

October 22, 2024 11:00 am

AI-Driven Simulation & Design Optimization Framework

Digital Engineering

October 22, 2024 11:30 am

Battery Modeling and Manufacturing Simulation - What's New

Electrification and ADAS

One of the biggest impediments to widespread adoption of electric transportation is battery cost. Performance, safety, and hitting time-to-market all remain challenges for the EV design cycle along with an evolving technological, supply chain and regulatory landscape for batteries. Tight product cycles make it impossible to use the build, test, fix approach against a multitude of battery design choices that exist at the material and component level. Simulation is therefore critical in EV and battery product development. Cell chemistry/format, manufacturing quality, cooling system and mechanical design significantly impact vehicle level attributes such as safety and performance with some tradeoffs involved. All of the components then need to be integrated and system performance validated against real-life usage conditions. On the safety side with new mandates that require passenger warnings around thermal runaway, propagation resistance becomes important whether thermally triggered or mechanically triggered. This presentation will cover an overview of Ansys battery solutions including key challenges in battery manufacturing, safety and how system level performance and what if failure scenarios can be investigated.

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Vidyu Challa, PhD
Ansys

October 22, 2024 11:30 am

New Electronics Design Capabilities

Electronics and Lighting

Automotive printed circuit boards (PCBs) are the heart of all modern vehicles as they play a critical role in all advanced electronic features including autonomous driving systems, safety, infotainment, and connectivity solutions. In this presentation we will be covering the latest advancements in electronics, thermal and mechanical simulations of PCBs using Ansys tools. The presentation will highlight newer technologies to create and solve complex PCB assemblies including connectors, flex cables and housing to investigate the performance of the complete sub system and not the components in isolation, which is critical for automotive applications. Full vehicle simulations will also be presented showing virtual electromagnetic compatibility (EMC) of PCBs installed inside the vehicle along with the electrical/electronics architecture.

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Juliano Mologni
Ansys

October 22, 2024 11:30 am

Accelerating Design Exploration (Discovery)

Digital Engineering

Capturing design insights earlier in the design process in a critical driver to shift-left initiatives, enabling increased innovation, reduced cycles times, and improved quality through earlier issue detection. Attend this session to learn how Ansys Discovery is leveraging native GPU computing and a next-generation integrated user experience to break down the barrier to upfront simulation across multiple automotive application areas, providing instantaneous design guidance where and when you need it most. Stop waiting for results and start acting on them.

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Justin Hendrickson
Ansys

October 22, 2024 11:30 am

Safety Considerations for AI in Automotive Applications

Safety and Systems

An overview of the new ISO Standard: ISO/PAS 8800 (Road vehicles Safety and artificial intelligence). This standards defines safety-related properties and risk factors impacting the insufficient performance and malfunctioning behavior of Artificial Intelligence (AI) within a road vehicle context. Emphasis on the key elements of this standard such as deviation of safety requirements, data quality and completeness, SW architecture measures for the control and mitigation of failures and the evidence required to support an assurance argument for the overall safety of an automotive system that employes AI. Real life challenges to the implementation of this standard will be also covered for selected design areas. Activities I am involved in at both Aptiv and ISO/SAE/SCC to address these challenges are also highlighted.

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Majed Mohammed
Aptiv

October 22, 2024 12:00 pm

Lunch

Meals

October 22, 2024 01:15 pm

Process Integration and Design Optimization (optiSLang)

Digital Engineering

Simulation has become an indispensable component of the modern product development cycle, enabling faster and more efficient design iterations. A critical aspect of this process is the digitalization and optimization of simulation workflows through the seamless integration of multidisciplinary computer-aided engineering (CAE) tools. In this presentation, we will demonstrate how to maximize the potential of your existing CAE tools by orchestrating and optimizing these workflows with Ansys optiSLang, the cutting-edge process integration and design optimization (PIDO) solution. By leveraging optiSLang, engineers can streamline complex simulations, reduce manual effort, and accelerate time-to-market. This talk will delve into key methodologies, including Sensitivity Analysis, Design Exploration, Optimization, and Robustness and Reliability assessments, showing how these approaches can improve product quality while mitigating risk and uncertainty in real-world applications.

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Ravi Teja Katragadda
Ansys

October 22, 2024 01:15 pm

Battery Thermal Runaway Mitigation

Electrification and ADAS

In this presentation, we will focus on EV battery thermal runaway propagation simulation. In such a simulation, we model the heat generation due to exothermal reactions during thermal runaway and the subsequent heat transfer of the heat to the cooling system. The exothermal reaction models are calibrated from the accelerating rate calorimetry (ARC) data of a battery cell. The heat transfer is modelled using conjugate heat transfer models in computational fluid dynamics (CFD). Modelling of venting and vented gas reaction is also discussed. Several validated examples will be shown in this presentation including module/pack runaway propagation and the associated venting and vented gas reaction.

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Xiao Hu
Ansys

October 22, 2024 01:15 pm

A Refined Approach in Sherlock Simulation to Assess Reliability of New Electronic Design and Assist Root Cause Failure Analysis

Electronics and Lighting

A refined approach will be discussed to accurately assess reliability of new electronic design, as well as to assist the root cause identification of validation test failures with confidence. This approach will measure important parameters of more vulnerable devices in new electronic design proactively, or to be reactive to validation test failures. A few real-world examples will be given to demonstrate this approach.

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Yong Hong
Harman International

October 22, 2024 01:15 pm

Using Medini Analyze for Functional Safety

Safety and Systems

How doing our FMEDAs in Medini instead of Excel: - Improved the quality of our analysis - Resulting in a higher confidence in our design. - Made extracting data on specific failures quicker, easier and more accurate - Made estimating the risk of missing/inoperative Safety Mechanism easier and more accurate Traceability matrix between SFMEA and FMEDA improved confidence in our design.

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Neil van Zyl
BorgWarner

October 22, 2024 01:45 pm

Electric Motor Design and Development - What's New

Electrification and ADAS

Ansys Electronics continues to demonstrate its multi-decade leadership in computational electromagnetics and multi physics simulations.

In the newest release 2024R2, the unmatched market leading and multiphysics motor design simulation software, Ansys Motor-CAD, now offers capabilities that are further widening the competitive gap. Some of these new capabilities are: three new cooling methods; extending the capability of the adaptive templates; and enhanced electromagnetics.

As an advanced electromagnetic field solver that widely used for electric machine design and analysis, Ansys Maxwell in 2024R2 now has: an improved formulation for the sliding mesh interface called Continuum Air; a new reduced order model(ROM) for brush commutating machines; and a new User Defined Primitive (UDP) for hairpin coil.

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Yijang Jia
Ansys

October 22, 2024 01:45 pm

EMI/EMC Simulation - Latest Capabilities from Chips to Full Vehicle

Electronics and Lighting

The design complexity of high-performance electronics systems, including chip-package-board and accompanying enclosures and housings and even entire systems such as electric vehicles (EV) has dramatically increased in recent years. With further requirements to integrate high-speed digital functionality for infotainment and safety systems such as HDMI, USB, DDR4, PCIe and UCIe, reaching compliance with EMI/EMC (ElectroMagnetic Interferences and Compatibility) standards has become ever more challenging. In addition, electromagnetic co-existence issues with RF wireless protocols such as AM/FM, Satellite Radio, WiFi, Bluetooth, ZigBee, and 5G/6G can potentially occur, causing signal integrity issues within and across systems resulting in bandwidth reduction and reduced performance. Finally, the push to EV technology with the demands for higher voltages and operating frequencies has introduced some of the most challenging problems in EV development. In the worst cases, addressing EMI/EMC issues requires a significant re-design of critical EV systems resulting in increased cost of design and delayed time to market. This presentation reviews the most recent advancements in electromagnetic simulation methodologies for virtual EMI/EMC testing covering the entire design spectrum from chips to systems on to full EV capacity.

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Matthew Commens
Ansys

October 22, 2024 01:45 pm

Session Title TBD - AI Topic

Digital Engineering

October 22, 2024 01:45 pm

A Holistic Approach to Prevent Unexpected Behavior in Autonomous Vehicles

Safety and Systems

Modern vehicles are getting more and more complex and an approach that utilizes industry best practices is needed to prevent the vehicle from behaving in ways that are unwanted and/or dangerous. This presentation describes an approach based on a process model, automotive functional safety and Safety of the Intended Function as well as automotive cyber security to prevent unexpected behavior. We will investigate how the process can be used to ensure that requirements are documented, understood and implemented. Then we will use ISO 26262:2018 to explain how unreasonable risk due to E/E malfunctions can be prevented. After that we will discuss the use of ISO 21448 (SOTIF) to prevent malfunctions caused by technological insufficiency and foreseeable misuse. The final layer of protection is achieved by using ISO 21434 cyber security to identify and analyze hacking attack risks.

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Heinz Bodo Seifert
TUV Rheinland Group

October 22, 2024 02:15 pm

Honda Material Intelligent Database for Highly Efficient and Environmentally Friendly R&D

Digital Engineering

Honda has been constructing a unique material intelligence digital platform using material database Granta for the purpose of highly efficient, environmentally friendly R&D. We’ve designed a material database structure ’schema’ , which is easy to be utilized for fields of design, simulation (functional and manufacturing CAE, additive manufacturing, materials informatics), additive, procurement, and material development.  Over thousand users in the company accesses to the in-house material database and we’re now tackling to enlarge its application for Honda products not only automotive, but motorcycle, power products, aerospace, and other technical fields. Besides, under VUCA circumstance for future, we suggest a prospective digital utilization on material information toward environmental, regulatory issues, and AI technology progress.

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Toru Furusawa
Honda R&D Co., Ltd

October 22, 2024 02:15 pm

Electric Powertrain Durability and NVH Prediction

Electrification and ADAS

The electric powertrain has become a pivotal component in modern electric vehicles (EVs), directly impacting their performance, efficiency, and user experience. Ensuring the durability and reliability of the electric powertrain is crucial for the long-term success of EVs. This study focuses on developing predictive models for the durability of electric powertrains, with particular attention to Noise, Vibration, and Harshness (NVH) characteristics, which are critical to both the perceived quality and mechanical integrity of the system. By integrating advanced simulation techniques, material fatigue analysis, and real-world testing data, the research aims to enhance the accuracy of durability predictions and optimize NVH performance. The findings provide insights into the key factors affecting powertrain longevity and noise reduction, offering valuable guidance for the design and engineering of more robust and quieter electric vehicles.

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Santosh Kottalgi
Ansys

October 22, 2024 02:15 pm

High Frequency Modeling of HV Bus Electric Power Conversion System

Electronics and Lighting

Developing a High Frequency (up to 10 MHz) Model of HV bus electric power conversion system in order to minimize conducted EMC, CM noise & leakage current through out the system and optimize CM filter design and cable shielding strategy.

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Arash Bavili
General Motors

October 22, 2024 02:15 pm

Why MBSE? MBSE at the Intersection of Safety and Systems Engineering in the Automotive Domain

Safety and Systems

Legacy approaches to automotive system design often consider systems engineering and systems safety analysis as critical yet separate engineering activities. This results in specialized but siloed and disconnected processes, ill-equipped to efficiently respond to industry trends of increasing product complexity and reduced development times. To counter these challenges, as in other industries, automotive systems engineering has adopted a Digital Engineering approach centered around a model-based representation of the design intent. However, unlike other industries, model-based work products in automotive are not a direct deliverable to our customers. Why then do we invest significant engineering resources into model-based systems engineering (MBSE)? This presentation will highlight the value proposition of closely coupling automotive systems engineering and safety workstreams via a shared, common SysML model. Discussion will include how the model enables an integrated development process where safety is designed into the system from day one. Additional return on modeling investment will be shown in the form of integrated system simulations, efficiencies in system verification and validation, and accelerated design certification and instantiation.

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Jeremy Ross
Ford

October 22, 2024 02:45 pm

Power Electronics Simulation

Electrification and ADAS

Modern vehicles put new demands on electronic devices and systems for the control and conversion of electrical power. Electrification promises more efficient powertrains with increased range, faster charging, and lower weight but they also introduce new sources of electromagnetic interference (EMI). The design and optimization of these systems are essential to achieving greater power density, efficiency, and reliability. This presentation will introduce the extensive simulation capabilities used to design and fine-tune power electronics, predict their behavior under both normal and faulty conditions, and proactively address potential issues – from analysis and sizing of power converter topologies to reduced-order modeling of electromagnetic components and electronics reliability.

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Peng Han
Ansys

October 22, 2024 02:45 pm

Lighting & Optical Simulation Overview and Technology Update

Electronics and Lighting

Lighting technology is significantly evolving. Displays are becoming larger, brighter, and multi-dimensional. Lighting systems are more customizable, flexible, adaptable and complex as ever. Imaging sensors are getting smaller, while image quality is getting higher. For many of these optical systems, challenges are being solved at the micro-level, but system-level integration and performance are equally as complex. With the Optics portfolio at Ansys, we can bridge the gap between microstructure optimization and system level performance. Many advances in our Optics products have enabled us to keep up with the evolving lighting & sensing technologies, such as improved GPU acceleration, stray light analysis, and full optical product workflows. Join to discover the Ansys Optics solution and its recent innovations.

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Mike Grove
Ansys

October 22, 2024 02:45 pm

Autonomy Use Case for Safety Analysis of Complex Models

Safety and Systems

The complexity of an open pit mining Fleet Management System (FMS) presents challenges for Medini Analyze FFMEA tools. The FMS is structured into four main architectural layersSite Operations, FMS, Autonomy, and Drive-By-Wire each containing multiple internal layers and many functions. The AIAG-VDA 2019 FMEA Handbook reflected in Medini does not directly provide a concept of system nesting or module reuse found in the design. This session explores an example of an open pit FMS and an approach using Medini to address its complexity. The approach is a work in progress, building on lessons from previous efforts and enhanced through collaboration with the Medini Analyze Expert Team.

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Andy Saxsma
Hexagon AB

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Varun Jayaram
Hexagon

October 22, 2024 02:45 pm

Update on Ansys Solutions for Aerodynamics and Thermal (Fluent)

Digital Engineering

Automotive external aerodynamics is a key factor in vehicle design, impacting aspects such as performance, fuel efficiency, stability, noise, and comfort. In electric vehicles (EVs), aerodynamic performance is especially critical as it significantly affects battery range and longevity. Moreover, EVs generate significantly less engine noise compared to traditional combustion engines, making aerodynamic designs crucial for achieving acoustic comfort. Another crucial area for the automotive industry is thermal management. Efficient thermal management systems help maintain the right temperature for the engine, battery, and other critical parts, ensuring optimal performance and longevity of vehicle components. This presentation will showcase the latest Ansys solutions in the field of aerodynamics and thermal management. We will also demonstrate how our Native Multi-GPU solver can accelerate simulations by an order of magnitude, enhancing the accuracy of aerodynamic predictions and enabling faster design iterations and better optimization. Lastly, we are thrilled to introduce our latest AI innovation, Ansys SimAI, which promises to revolutionize data-driven design.

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Marco Coderoni
Ansys

October 22, 2024 03:15 pm

Break

Meals

October 22, 2024 03:30 pm

Update on Ansys Solutions for Structural and Durability (Mechanical)

Digital Engineering

Structural simulation and Durability prediction is paramount to next generation vehicle validation which ensures the reliability, safety, and performance of vehicles under various conditions like different loading conditions, environments, and usage scenarios. Electrification, rapid technology advancements and shorter product development cycles demands rapid advancements in simulation best practices in a form of new modeling & meshing practices, different connection types, innovative simulation workflows, solver accuracy, performance, high performance computing, incorporation of manufacturing aspects into simulation, test correlation at different stages and ability in running end to end durability workflows to automate process of durability performance improvement. In this presentation, we will show how Ansys structural and durability solutions will help deliver next-generation vehicles that provide a safer, more comfortable passenger experience. We will cover different approaches customers are adopting both solver and workflow perspectives for component, system and vehicle level simulations.

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Hardik Shah
Ansys

October 22, 2024 03:30 pm

Exterior Lighting Design Capabilities: How to Simulate the Latest Lamp Technologies

Electronics and Lighting

The design of automotive lighting requires a deep understanding of optical, thermal, electronics, and structural domains to comply with stringent legal requirements. The complexity of automotive lighting systems and the integration of their subsystems necessitate feedback across these different physics domains. This presentation will address several key aspects, including the optical design considerations of automotive lighting, which involve optical design principles, light source creation, materials definition, and the integration of data across various software platforms. It will also explore the capabilities of automotive lighting in validation and optimization, aiming to enhance product workflows while reducing costs and time to market. Furthermore, we will illustrate how high-fidelity computer simulations can be utilized to understand the effects of these physics domains and their interactions on automotive lighting design, which is crucial for achieving operational success, refining design decisions, and accelerating the product lifecycle.

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Akshay Patke
Ansys

October 22, 2024 03:30 pm

Advancing Software Safety through Test Automation using Advanced Engineering(SCADE) and Gen AI tools

Safety and Systems

Advanced software engineering tools can be used to generate test cases and test case sets of inputs and expected results.  This presentation will go through examples of using SCADE tools to generate test cases for models as well as exploring natural language processing based tools including generative AI to develop test cases.

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Luke Zeleznak
Honeywell Aerospace Technologies

October 22, 2024 03:30 pm

Self-Driving Car Safety Through Accurate Simulation at Scale

Electrification and ADAS

Join us for an exclusive presentation where Ansys unveils the future of highly automated driving. Discover how we tackle the engineering challenge of ensuring safety across diverse scenarios through model-based systems engineering. Our approach to safety encompasses design integration, verification and validation, and incremental safety case development, all supported by advanced simulation and analysis. You will also gain insights into Ansys's commitment to safety and simulation at scale, highlighted by an exclusive testimonial from OEM customers introducing the 'Personal Pilot L3' in the new BMW 7 Series.

 

During the presentation, you will learn how to effectively integrate safety into design and verification processes, navigate system limits with a focus on safety and SOTIF (Safety of the Intended Functionality) during development and validation, and utilize synthetic sensor data for perception machine learning and AI training and validation. Additionally, you will explore how to leverage simulation at scale to validate autonomous driving features, including sensitivity and reliability analysis in scenario-based simulations.

Keywords include simulation, virtual testing, toolchain, sensor, functional safety, SOTIF, safety case, MBSE (Model-Based Systems Engineering), synthetic data, machine learning, AI, radar, camera, lidar, ultrasonic, sensor fusion, and cloud.

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Tony Karam
Ansys Inc

October 22, 2024 04:00 pm

Interior Lighting, Cockpit Glare and Reflection Optimization

Electronics and Lighting

Vehicle vision ergonomics are becoming more and more relevant in todays automotive market. The comfort and safety of the passengers in a vehicle might be affected by different natural and artificial light sources. Interior lighting, sun reflections, displays and external lamps must be taken into consideration during the development of an optimum cabin. The human factors are no longer a subjective topic, and thanks to Ansys Speos and its virtual human vision capabilities, an infinite number of scenarios can be assessed, and a robust design can be achieved.

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Victor Loya
Ansys

October 22, 2024 04:00 pm

ADAS Sensor Models (AVx Sensors)

Electrification and ADAS

ADAS/Autonomous vehicle Software is very complex as SAE level 5 autonomous vehicle probably will have 1B SLOC vs 14 M SLOC in Boeing Dreamliner (As per Bloomberg energy report). Testing of such complex software is challenging and also time consuming. Product quality and maturity for such high complex ADAS/AV is function of testing at various levels like SW testing, integration testing, System Qualification Testing and vehicle testing. With conventional approach ADAS features get tested only at fag end of the project as it requires availability of vehicle with fully equipped sensors and actuators needed. This is extremely risky for meeting the stringent quality standard of safety critical systems, and extremely expensive. With development and maturation of artificial scenario and sensors simulation, Virtual Validation is gaining prominence as it address all demits of conventional development and testing approaches and gives edge by left shifting features testing along side of SW development. With increasing fidelity of simulation and realistic visual orchestrations, feature function testing gets left shifted and performed at bench level and use vehicle to measure Key Performance Indicators. With developments on physics based Radar model from companies like Ansys (AVx) enable configuration of antenna properties and give out ADC signal level data Virtual RWUP will gain prominence and minimize expensive Real World user Profile tests (RWUP) in real vehicle, and also enhance coverage of testing towards Safety of Intended Functionality (SOTIF) standards. Smart tradeoff between tests segregation between vehicle and simulation, makes projects execution faster, and cost effective.

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Venkatesulu Bhajanthri
Aptiv

October 22, 2024 04:00 pm

Reducing Software Verification Lead-time with SCADE Model Coverage Analysis for Safety Critical Systems

Safety and Systems

Among aircraft systems, the Fly-by-Wire (FBW) system is one of the most safety critical and it matures throughout the flight test campaign. During the campaign, many software loads are released, and several software verification activities must be satisfied before each of those software loads are allowed to be flown. At EMBRAER, SCADE has played a pivotal role for over 15 years in allowing the quick deployment of FBW software releases used throughout all its business units.   The latest version of SCADE is being used by EMBRAER in the development of the FBW for EVE - a leader in EVTOL industry. The brightest new feature in this latest version is SCADE Model Coverage Assistant (MCA), which is being used for the first time. This discussion will describe how EMBRAER believes how SCADE MCA will considerably alleviate verification activities and reduce software lead-times during the most strenuous phase of the aircraft development.

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Charin de Silva
Embraer

October 22, 2024 04:00 pm

NVIDIA's AI Solution for CAE Tools

Digital Engineering

NVIDIA Modulus is a state-of-the-art, open-source scientific machine learning platform that enables research, development and deployment of surrogate ML models for a wide range of engineering applications, such as external aerodynamics, cabin cooling, electro thermal cooling simulations etc. The platform offers training pipelines that enable development of optimized and scalable end-to-end workflows for ingesting large simulation datasets, training models in a distributed manner on multiple GPUs, physics-based validation and ease-of-deployment. It offers unique tools for embedding physical constraints derived from governing equations into ML models to increase their robustness and accuracy state-of-the-art model architectures. It also offers specialized ML model architectures that cater to specific engineering applications. In this talk, we will demonstrate these capabilities of the NVIDIA Modulus platform to Develop end-to-end training pipeline for building surrogate models Show the benchmarking workflow to evaluate and validate different model architectures This will be demonstrated in the context of two use cases external aerodynamics and structural analysis of cars.

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Dr. Rishi Ranade
NVIDIA

October 22, 2024 04:30 pm

Taking HUD Design to the Next Level (Speos)

Electronics and Lighting

Heads Up Display (HUD) systems present information within the driver's field of view, allowing them to keep their eyes on the road at all times. HUD systems have been around for over half a century, but a renewed interest and investment in this technology is currently taking place. This is being driven, in large part, by the advent of Advanced Driver Assistance Systems (ADAS) where the need to display safety-critical information effectively, with minimal distraction, is essential. To keep up with the growing demand and complexity of HUD systems, engineers need a fast and effective way to design, optimize, test, and validate them. This includes defining functional specifications & quality targets, assessing key performance metrics, and visually perceiving the system as the driver would. Ansys optical solutions provide purpose-built tools and workflows to virtually design, assess and test a HUD prototype under various driving conditions. This presentation will demonstrate how optical simulation and virtual prototyping can help solve the challenges of HUD design.

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TJ Gilleran
Ansys

October 22, 2024 04:30 pm

Streamlining EVs from Design to Operations with Hybrid Digital Twins

Digital Engineering

In the drive towards an electrified and sustainable future, automotive companies are increasingly adopting simulation technologies to accelerate design cycles and reduce costs. As technology complexities escalate, there is a growing need for an integrated development approach that emphasizes early-stage development and validation processes. Engineers are turning to simulation to address complex system requirements, but achieving comprehensive system validation through virtualization requires the creation of high-fidelity, physics-based plant models. These models, calibrated using machine learning and integrated with software functions and real-world driving scenarios, enable a virtual replication of the vehicle. Moreover, companies are now extending these models from product development into operational phases, leveraging the power of Hybrid Digital Twins for real-time fleet management. In this session, Ansys experts will explore the use of simulation methods, reduced-order models (ROMs), and AI/ML techniques for performance validation through model-in-the-loop (MIL), hardware-in-the-loop (HIL), and virtual drive tests. The discussion will also cover how to combine data and physics to create hybrid digital twins, which offer online insights into component operation through virtual sensors, predict service life, and optimize operating conditions. Key takeaways include understanding Hybrid Digital Twins—why and how to implement them, high-fidelity system simulation through reduced-order models, integrating test and 1D data with 3D data for accurate virtual validation, and the role of virtual sensors in predictive maintenance, all powered by physics and refined by data.

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Vitor Lopez
Ansys

October 22, 2024 04:30 pm

Image Injection HIL Solution for Adaptive Driving Beam Development and Testing

Electrification and ADAS

This joint presentation by Jeff Blackburn of Ansys and Chris Manning of dSPACE will discuss the new FMVSS-108 Adaptive Driving Beam (Smart headlamp) regulations, and how SiL and HiL simulation can be used to greatly reduce the need and inconvenience of track and road nighttime physical testing, saving time and money Integrating the Ansys AVx physics accurate camera and headlamp models with the dSPACE ASM 3D driving simulator and vehicle dynamics models yields a SiL virtual twin of your vehicle and ADB exterior lighting system allowing you to test your ADB headlamp function and control logic virtually on the desktop. 

Using a dSPACE HiL bench with an ESI (environmental sensor interface) module, the Ansys AVx simulation generated raw image frames can be directly injected into the real camera’s image processing chip. This let’s you test the ADB headlamp function and control logic using the real camera’s perception software in the convenience of the lab, versus having to send your engineering team out at night.

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Jeff Blackburn
Ansys, Inc.

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Chris Manning
dSPACE Inc.

October 22, 2024 04:30 pm

Safety and Systems Track: Session to be Announced

Safety and Systems

October 22, 2024 05:00 pm

Track Wrap Up: Electrification and ADAS

Electrification and ADAS

October 22, 2024 05:00 pm

Track Wrap Up: Electronics and Lighting

Electronics and Lighting

October 22, 2024 05:00 pm

Track Wrap Up: Safety and Systems

Safety and Systems

October 22, 2024 05:00 pm

Track Wrap Up: Digital Engineering

Digital Engineering

October 22, 2024 05:30 pm

Networking Reception

October 23, 2024 07:30 am

Exhibits Open

Exhibition

October 23, 2024 07:30 am

Continental Breakfast

Meals

Walk the exhibition space to grab your quick breakfast before general session.

October 23, 2024 07:30 am

Registration

Registration Desk Open

October 23, 2024 07:30 am

HPE | AMD Invitation-Only Roundtable

Next gen CAE: Setting a new standard for product development with HPE and AMD 

To effectively support and scale their Ansys applications, manufacturers must enhance engineering productivity, become more data-driven, meet sustainability goals, scale flexibly, and increase profit margins.  Hewlett Packard Enterprise and AMD have teamed up with Ansys, the premier provider of CAE software, to help revolutionize product design. Our next-generation CAE solutions deliver virtually unlimited capacity and industry-specific tools to speed up design cycles and lower total cost of ownership (TCO). 

Join us to explore how you can optimize your CAE infrastructure for all your Ansys applications. Bring your questions and let’s shape the future of engineering together! 

October 23, 2024 07:30 am

TotalCAE Invitation-Only Roundtable

The Impact of AI/ML in the Product Development Process 

Artificial intelligence (AI) and machine learning (ML) have emerged as a potential transformative force in product development. This round table will explore the pivotal role of AI and ML in shaping the future of product design and optimization. We will delve into how these technologies streamline the speed and quality of the development process, AI/ML challenges and limitations that we can work together on addressing, and how to get started in testing these technologies. 

October 23, 2024 08:30 am

Digital Transformation and MBSE Workshop

Join us for an in-person hands-on workshop as we aim to explore solutions for digital transformation initiatives. Discover the tools to optimize processes faster with greater efficiency, and be inspired to design, build, and work in new ways. Gain insight into how digital transformation challenges are being addressed with innovative solutions by thought leaders and industry experts. Attendees are asked to bring a laptop for the hands-on portion of the Workshop.​

8:30 AM - 8:45 AM Welcome/Opening  
8:45 AM – 9:15 AM Industry guest speaker 
9:15 AM – 10:10 AM MBSE Hands-on workshop - part 1 
10:10 AM - 10:30 AM Break
10:30 AM - 12:30 PM MBSE Hands-on workshop - part 2 
12:30 PM - 1:00 PM Lunch
1:00 PM - 1:30 PM MBSE Hands-on workshop - closing

October 23, 2024 08:30 am

Digital Safety Workshop

Join us and the industry leaders from automotive and semiconductors in this in-person hands-on technical workshop focused on model-based safety analysis. We recommend the participants who plan to join bring their laptops for the hands-on experience.

8:30 AM – 8:45 AM Welcome/Opening  
8:45 AM - 9:40 AM Safety Product and the Collaboration Platform 
9:40 AM - 10:10 AM Guest speaker - CS Group 
10:10 AM - 10:30 AM Break 
10:30 AM - 12:00 PM Hands-On Workshop for DSM and Safety Cases 
12:00 PM - 1:15 PM Lunch 
1:15 PM - 2:30 PM Hands-On Workshop for Digital Engineering at Ansys 
2:30 PM - 3:00 PM Break 
3:00 PM - 3:30 PM AI for safety and cybersecurity analysis 
3:30 PM - 4:50 PM Safety of AI 
4:50 PM - 5:00 PM Wrap Up & Closing 

October 23, 2024 08:30 am

Embedded Software Workshop

Join us and the industry leaders from automotive and semiconductors in this in-person hands-on technical workshop focused on model-based safety analysis. We recommend the participants who plan to join bring their laptops for the hands-on experience.

8:30 AM – 8:45 AM Welcome/Opening  
8:45 AM - 10:10 AM Hands-On Workshop Part 1: Architecture and Design of Embedded Software 
10:10 AM - 10:30 AM Break 
10:30 AM - 11:00 AM Academic Guest Speaker (UNAQ): Adoption of SCADE in a Full Academic Program 
11:00 AM - 12:00 PM Hands-On Workshop Part 2: Software Implementation and Verification 
12:00 PM - 1:15 PM Lunch 
1:15 PM - 1:45 PM Hands-On Workshop Part 3: System / Software Integration 
1:45 PM - 2:30 PM From Fail-safe to Fail-operational: Model-Based Solutions for Automotive Embedded Controls of the Future 
2:30 PM - 3:00 PM Break 
3:00 PM - 4:00 PM Hands-On Workshop Bonus: Ansys Innovations with Scade One 
4:00 PM - 4:30 PM Wrap Up & Closing 

October 22, 2024 07:30 am

Exhibits Open

Exhibition

October 22, 2024 07:30 am

Continental Breakfast

Meals

Walk the exhibition space to grab your quick breakfast before general session.

October 22, 2024 07:30 am

Registration

Registration Desk Open

October 22, 2024 08:30 am

Engineering the Road Ahead with Simulation

General Session

As the Transportation industry evolves and innovates to deliver upon the goals of clean and safe mobility, efficient engineering processes are critical.   A key enabler in shortening and making the engineering processes more efficient is simulation. Visionary automotive companies know how their world-changing ideas will perform well before prototypes and production through the use of simulation and model-based systems engineering.  No longer relegated to CAE departments, simulation has changed tremendously over the past few years, empowering every engineer to innovate faster than ever before. Learn how the latest technologies in AI/ML, physic-based numerics and cloud services have transformed workflows to deliver the latest innovations in electrification, ADAS/AD, SDV, and vehicle attributes.

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Judy Curran
Ansys, Inc.

October 22, 2024 09:05 am

Pushing the Performance Limits: How Ansys powers Oracle Red Bull Racing's Competitive Edge

General Session

The use of numerical tools and virtual analysis plays a critical role in the design and optimization of Formula 1 cars.  To deliver race-winning performance on the track, Oracle Red Bull Racing relies on virtualized design and development to reproduce real-world scenarios and re-create the complex physical environment off the track. This continuous and rapid process ensures the car is optimized for maximum performance at each racetrack. 

Gennaro will highlight how Oracle Red Bull Racing leverages Ansys technologies for aerodynamic development and thermal management to the virtual testing of impact structures. Through the accuracy and fidelity in reproducing virtual testing environments, Ansys enables the Team to reduce costs and time necessary for physical prototypes, enabling quicker iterations and innovations in the fast-paced world of Formula 1. The Innovation Partnership with Ansys is crucial for Oracle Red Bull Racing to maintain the competitive edge in Formula 1 and to deliver exceptional performance on and off the track. 

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Gennaro Serino
Oracle Red Bull Racing

October 22, 2024 09:40 am

Safety Simulation Enhancement Using AI

General Session

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Rajkumar Rajagopalan
STELLANTIS

October 22, 2024 10:05 am

GHBMC and the Applications of GHBMC Models

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Chin-Hsu Lin
General Motors Research and Development Center

October 22, 2024 10:30 am

Break

October 22, 2024 10:45 am

Virtual Validation of Seat Integrity in a Full-Size SUV for Front Crash

Crash I

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Reza Bihamta

October 22, 2024 10:45 am

Simulation Multi-stage draw and ironing for making battery cell by LS-DYNA

Forming I

October 22, 2024 10:45 am

Development of Human Body Model (HBM-C) and Accelerated Positioning Tool (APT-C) for Virtual Testing and Product Development

Occupant and Pedestrian Safety I

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Renuka Jagadish

October 22, 2024 10:45 am

Application of Machine Learning technique to incorporate manufacturing and Testing variation for Robust BIW design for Crash performance

Simulation Methods I

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Shinoj Nair

October 22, 2024 11:10 am

Collapse Load Calibration for Engine Mounts

Crash I

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Bruno Pocksznicki

October 22, 2024 11:10 am

Highly Automated Springback Compensation of the Draw Die

Forming I

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Xinhai Zhu
Ansys

October 22, 2024 11:10 am

Preliminary Validation of New Continuum Particle Gas (CPG) Method for Airbag Deployment Simulations

Occupant and Pedestrian Safety I

For airbag deployment simulation, CPM is widely used due to its usability and cost performance. On the other hand, it has some difficulty in representing the gas flow into the narrow space like curtain side airbags. CPG is a new method which solves the Navier-Stokes equation for a space discretized by particles, and is expected to be able to solve his problem by representing pressure propagation and its effect to the fabric more accurately. This paper shows the preliminary validation results comparing test results and CPM for several airbags. CPG shows some better behaviors compared to conventional methods and possibilities to apply to the airbag deployment simulations.

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Hiromichi Ohira
JSOL Corporation

October 22, 2024 11:10 am

Simulating Solder Joint Shapes Post Reflow in Flip Chip Ball Grid Array Packages using ISPG – part 1

Simulation Methods I

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Daniel Vilyatser

October 22, 2024 11:35 am

Virtual validation of HIT: identification of key parameters to achieve ECE-R21/FMVSS201 requirements

Crash I

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Simone Calcopietro

October 22, 2024 11:35 am

Hot Forming Simulation with Ansys Forming and LS-DYNA

Forming I

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Volker Steininger

October 22, 2024 11:35 am

Utilizing a validated laminated glass model to simulate pedestrian head impact on a windshield

Occupant and Pedestrian Safety I

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Marc Tatarsky

October 22, 2024 11:35 am

Simulating Solder Joint Shapes Post Reflow in Flip Chip Ball Grid Array Packages using ISPG – part 2

Simulation Methods I

Accurate simulation of solder joint shapes and dimensions during the Flip Chip Ball Grid Array (FCBGA) packaging reflow process is crucial for ensuring signal integrity and structural reliability in electronic devices. This presentation introduces a novel approach utilizing the adaptive Incompressible Smooth Particle Galerkin (ISPG) method in LS-DYNA.   Our methodology involves calibrating the ISPG model using NVIDIA's FCBGA, where a set of optimal parameters was identified. To validate the calibrated model, various FCBGA designs were simulated and compared against experimental solder joint cross-sectional data. The results demonstrated a strong correlation between the calibrated model and the experimental data, confirming the high accuracy of the ISPG method.  This study highlights the significant impact of ISPG material model parameters on solder joint morphology, aiming to improve the design process by identifying key parameters.

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Yogev Buzaglo
NVIDIA

October 22, 2024 12:00 pm

Sponsored Lunch - HPE | AMD

Buffet lunch will be served during:

Advancements in Sustainable HPC Solutions for Ansys Applications

At this lunch presentation AMD and HPE will address the complex simulation challenges faced by our enterprise CAE customers. This session will focus on the deployment of highly efficient high-performance computing (HPC) clusters, power management options, advanced storage systems, and robust data management solutions. With customers relying on advanced modeling and simulation as a key business function, it’s important to choose HPC systems that optimize performance for a wide range of applications. Additionally, as thermal and power management become increasingly critical in next-generation HPC systems, customers need to understand the advantages of liquid cooling technology.

Join us to also hear about the latest performance results of AMD EPYC™ processors running Ansys CFX, Ansys Fluent, Ansys Mechanical, and Ansys LS-DYNA, demonstrating their capabilities in real-world applications.

October 22, 2024 12:00 pm

Sponsored Lunch - TotalCAE

Buffet lunch will be served during:

Case Studies in Utilizing High Performance Computing (HPC) and AI/ML for Digital Transformation

High-performance computing (HPC) and AI/ML accelerate solving complex simulations at unprecedented speeds to innovate faster.  This talk will focus on case studies of clients utilizing TotalCAE-managed HPC services for clusters and cloud to accelerate their digital transformation using HPC, cloud, and AI/ML for their CAE workflows.

October 22, 2024 12:00 pm

General Lunch

October 22, 2024 01:15 pm

Computational modeling of tensile split Hopkinson bar tests on carbon-carbon composites using continuum and mesoscale approaches

Aerospace Structure Impact and Dynamics I

The high strength, toughness, quasi-ductility over monolithic ceramics, and elevated temperature oxidation resistance make carbon-carbon (C/C) ceramic matrix composites (CMCs) excellent candidates for hypersonic vehicle components expected to experience high strain rates and high temperatures in service. However, accurate characterization of the material behavior under such extreme/harsh conditions presents significant challenges. This work will present the results of LS-DYNA computations conducted in support of an ongoing Southwest Research Institute (SwRI) internal research (IR) program focused on the high temperature, high strain rate behavior of C/C composites. The goal of this IR program is to develop and fabricate a system capable of rapidly heating metals and C/C CMC test specimens up to 4000°F to facilitate elevated temperature tensile split-Hopkinson pressure bar (SHPB) testing. This talk will provide an overview of SwRI’s dynamic material testing capabilities, challenges associated with the current effort, and will primarily focus the use of explicit finite element (FE) simulations to support the experimental program. Results of a computational investigation into apparent non-equilibrium behavior exhibited in previous SHPB tension tests conducted on a commercially available C/C composite material will be presented. Said non-equilibrium behavior is suggested by the measured signals on the input and output bars during these tests, particularly the dissimilarity of the transmitted wave and the sum of the incident and reflected waves. In the computations, the entire SHPB set up is represented/meshed. Two different approaches are taken to model the SHPB tension test coupons. The first approach considers the woven C/C CMC as a smeared homogeneous continuum. These continuum simulations resulted in sudden, brittle failure, which leads to wave attenuation/dispersion of the transmitted strain signals (i.e., the transmitter bar strain signals decrease in amplitude with increasing propagation distance). To correlate the simulated and experimental strain amplitude at the location of the transmitter bar strain gage in the tests, it was found that the value of the maximum principal stress at failure in the continuum models needed to be increased to what the authors believe is an unrealistically large value. It was also found that the continuum modeling approach is unable to capture the widening of the transmitter bar signals that is present in the SPHB experimental data. In the second modeling approach, the woven C/C CMC mesostructure (i.e., the tows and matrix) was explicitly modeled. Compared to the continuum simulations, the mesoscale simulations exhibited a more progressive failure, which was found to result in enough additional “ductility” such that the amplitude of the strain and force signals did not decrease with increasing propagation distance along the transmitter bar. Additionally, the mesoscale simulations resulted in transmitted strain signals that were wider those in the continuum simulations and were in good agreement to those in the experiments. Whereas the maximum principal stress at failure used in the continuum models had to be unrealistically increased to correlate the simulated transmitted strain signals to those in the experiment, this was not the case for the failure properties used for the tows and matrix in the mesoscale simulations, highlighting the importance of the mesoscale approach.

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Christopher Sorini
Southwest Research Institute (SwRI)

October 22, 2024 01:15 pm

Emergency Brace Positioning and Injury Risk Prediction of Aircraft Occupants under Impact Loading

Human Body Models

THUMS (Total Human Model for Safety) is a detailed biofidelic finite element model of the human body, which encompass different genders and physiques including detailed anatomical features of the skeletal structure, internal organs, and other soft tissues like skin, flesh, and ligaments. The application of THUMS in numerical simulation offers exciting opportunities in automotive and civil aerospace development in areas such as safety, comfort, and ergonomics. These models will play an increasingly important role in the study of human body kinematics and assessment of injury risks in collision accidents.   The Civil Aviation University of China (CAUC) aims to establish a posture database according to civil aviation standards and perform detailed numerical studies on the biomechanical response of aircraft occupants using THUMS in a variety of simulated impact scenarios. CAUC collaborated with Arup and its software house Oasys LS-DYNA, to help build this posture database and explore the feasibility of using Oasys PRIMER (a world leading LS-DYNA pre-processor) with its comprehensive human body model positioning tools and THUMS positioning metadata to achieve complex emergency braced postures.  This presentation describes the entire positioning workflow used to achieve complex brace postures using the multi-stage positioning method in Oasys PRIMER and the *CONTROL_STAGED_CONSTRUCTION keyword in LS-DYNA. Further investigations were made to optimize simulation run times. Using a generic aircraft seat, a series of standard dynamic load cases are performed to predict occupant kinematics and the extent of injury risk to the aircraft occupant. This research will contribute to the wider application of THUMS in the aviation industry and promote biomechanical research into aircraft occupant safety.

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Emily Owen
Oasys LS-DYNA Environment

October 22, 2024 01:15 pm

Sonic weld characterization and FEA modeling method development for automotive applications

Material and Constitutive Modelling I

Joining is a critical part of any structure for transferring load and maintaining integrity for the product. Ultrasonic weld is one of the popular methods for joining plastic parts in automotive industry. Along with providing a visually demanding finish, the method has been established for tight, strong, and dimensionally accurate joints. With the increase of complexity and integration of electrical and sensing instrumentation in autonomous and electric vehicles, ultrasonic weld provides a necessary means of attaching parts into plastic parts without compromising visual impact. However, the sonic weld performance is yet to be quantified, and the criteria for capturing weld separation, and losing this connected load path during structural vehicle analysis, has not been studied extensively.  Sonic welds, even though it is a very effective joining method, the whole welding tooling process is expensive and time consuming. Ideally, to optimize the welding spot number and develop future cost-effective welding method, it is crucial to understand the actual weld performance under various variables such as material, thickness, temperature, strain rates etc.  In the following study, sonic weld performance has been evaluated in five different material combinations, three different strain rates and three different temperatures. Based on the analysis, a fully characterized FEA sonic weld modeling method has been developed, which captures weld separation, for in-production parts joined with sonic welding method. This method can be applied on full vehicle level analysis, like front and rear low speed, and enables for optimized design by determining an ideal number of sonic welds necessary for this type of structural loading.

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ABM Iftekharul Islam
General Motors

October 22, 2024 01:15 pm

An Application of Shape Similarity Recognition Using PCA based Dimensional Compression

SDM

In recent years, the speed required for product development has increased significantly. With the increasing sophistication of requirement levels, data-driven development utilizing past data is gaining attention in the automotive industry. Compared to physical testing, simulation is characterized by the ease of obtaining information through calculation and analysis, but on the other hand, handling huge amounts of data is a challenge. In this paper, we propose a new process to search for similar behavior of the part of interest from dozens of crash simulation results by using the order-reduction technique. Assuming that an irregularity occurred in the behavior of a member, the modeling history database was searched for members with similar irregularities using the shape of the member as a key, and highly similar behaviors were found in the database.

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MASAHIRO OKAMURA
JSOL Corporation

October 22, 2024 01:40 pm

Adaptive FEM-SPH Numerical Models of CFRP Composite Materials under Hypervelocity Impacts

Aerospace Structure Impact & Dynamics I

Impacts at or exceeding speeds of 7 km/s are classified as hypervelocity impacts (HVI). Micro-meteorites and space debris travelling at these speeds pose a present and prevalent threat to the operational safety of satellites. The damage can be measured through loss of operation and the corresponding economic expenses. HVIs against satellite shielding structures need to be understood to improve their design, however, physical testing is usually associated with high economic expenses. A commonly accepted and widely used alternative relies on numerical modelling of HVI shielding structures. More recently, the use of advanced composite materials in space applications, such as carbon fiber reinforced polymers (CFRPs), has increased. This necessitates the development of accurate numerical modelling techniques adept at predicting failure mechanisms and damage under these extreme loading conditions. Generally, numerical techniques employed in HVI modelling rely on the Lagrangian implementation of the finite element method (FEM; well-suited for tracking relative motion between interfaces, useful in modelling delamination) or the meshfree smoothed particles hydrodynamics method (SPH; excellent for replicating extreme deformation and fragmentation). To leverage the benefits of both methods and capture the wide range of failure mechanisms and damage occurring simultaneously, this study employs an adaptive FEM-SPH method. 16-ply laminated composites under HVI by three different types of orbital debris (steel, aluminum and nylon, classified as high, medium and low-density materials by NASA, respectively) are studied. Crater size and delaminated area are used as comparison metrics to gauge the accuracy of the numerical models and variations in the prediction of these features are explored and quantified across different composite material models.

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Anthony Gudisey

October 22, 2024 01:40 pm

Introducing HBMs in Safety Simulations. Biofidelic positioning, and post-processing with ANSA and META

Human Body Models

HBMs have become a much-needed tool for the safety simulations of the automotive industry. Out-of-position load cases for passengers and simulations for other vulnerable road users, like pedestrians and cyclists are increasingly needed, and HBMs can address this need. Euro NCAP in its Vision 2030 plans to replace ATDs with HBMs and the same is expected by other consumer information programs.  Nevertheless positioning, pre-processing and post-processing of these models on a level suitable for industrial use has not been straight-forward until now.  ANSA, offers a novel solution to this complex problem, making the positioning and handling of an HBM, as easy as with an ATD model. Using an advanced integrated MBD solver in parallel with morphing algorithms, engineers are provided with real time articulation and positioning of a HBM within an easy user interface. While the user just articulates the human model with the mouse in a most direct way, the biofidelic joint modelling guarantees realistic model movements and the generation of a ready-to-run model without the need of pre-simulation.  In parallel we are developing tools to tackle the problem of producing variants of an HBM adapting it to different anthropometries, thus better representing the population variability. We are addressing the problem with morphing and remeshing tools along with methods of incorporating anthropometric data into our algorithms.  Vulnerable road users is another area of great interest where HBMs are the only choice. We are conducting our own research projects related to cyclists' postures. Through statistical processing of laboratory scanned data we aim to produce statistical rider models that will be applied on the HBMs. This gives the possibility to the engineers, to simulate crash events of any kind of bicycle for any rider anthropometry.  On the post-processing side, running interactively or in batch mode, the META HBM tool automatically creates PPTX and PDF reports including videos and images of GHBM's kinematics, strain contour plots, elements erosion identification, chest-bands deformations, and injury criteria calculations (Brain CSDM, Abdominal soft tissue organs SED, etc.). Moreover, time history results can be extracted from the Occupant Injury Criteria tool. Injury criteria like HIC, BrIC, Nij, etc. are calculated. The extracted and calculated results can be compared to corresponding results of Anthropomorphic Test Devices (ATDs), while it is also easy to make comparisons between multiple HBMs simulation runs or between results from different solvers.

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Lambros Rorris
BETA CAE SYSTEMS INTERNATIONAL AG

October 22, 2024 01:40 pm

From Test to Calibrated Material Card using AIaugmented Workflows - A Case Study with Industrial Material for Aerospace and Automotive Applications

Material and Constitutive Modeling I

October 22, 2024 01:40 pm

Facilitating Virtual Testing at an Industrial Level by Simulation Data Management

SDM

From an industrial or productive standpoint, the scale of simulation   models, the number of involved simulation model components, and the complexity of the utilized processes with a vast amount of data are at a level that is challenging to manage manually. The introduction of virtual testing adds to the complexity of the development process and the quantity of data to be handled. Consequently, the use of an SDM system for this purpose can be advantageous in numerous ways.  The introduction of virtual testing can be accomplished in several steps. The initial step is the automation of data preparation, encompassing both input data and produced result data for both the OEM and the testing authority. Subsequent steps involve the implementation of individual processes and security mechanisms against data manipulation. This paper/presentation primarily addresses the initial step and outlines a methodology for achieving the objective of safeguarding against data manipulation and intellectual property (IP) infringem

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Marko Thiele
SCALE GmbH

October 22, 2024 02:05 pm

Bird Strike Resistance of Thermoplastic Composite Panels: Experimental and Numerical Analysis

Aerospace Structure Impact and Dynamics I 

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Aswini Kona Ravi

October 22, 2024 02:05 pm

HANS meets the GNS software Working with HBMs in Generator4 and Animator4

Human Body Models

Current trends and developments in the automotive market have caused changes in the way we evaluate and analyze our vehicles. Reacting to a growing demand for realism in simulations, Hans was born. Hans is the DYNAmore's human model, characterized by its detail and excellent performance. Realistic Human Body Models (HBMs) are one of the major revolutions in the world of vehicle development simulation nowadays. But the greater realism of the models comes together with a greater complexity in their handling. GNS offers its well-known products in response to this new need: Generator4 and Animator4 . Thanks to Generator4, Hans and other HBMs can sit comfortably through a simple GUI that is as flexible as the model itself. An industry that requires high realism in passenger models also expects a high level of accuracy in capturing the effects of changing model position and interaction with its environment, reflecting seat deformations and realistic positioning of anchoring systems.

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leyre Benito Cia
GNS mbH

October 22, 2024 02:05 pm

Polymer Calibration using Generative AI-powered Workflows

Material and Constitutive Modeling I

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Suri Bala

October 22, 2024 02:05 pm

Template-driven management of model and loadcase variants for LS-DYNA simulations

SDM

In recent years, crash and safety simulations have reached a very high level of accuracy in the prediction of the crashworthiness of the vehicle and the probability of injury for occupants and pedestrians under a multitude of loading scenarios. Among several factors, this achievement is also attributed to the fine resolution of finite element models that enables the precise representation of even the smallest parts and geometric features affecting the simulation results and the increase in the number of simulated loadcases. However, accuracy does come with a cost: Model size and variability have considerably increased, together with the number of loading scenarios that need to be simulated on each model variant.  From the definition of the different model variants from the CAD structure and the subdivision of the simulation models into functional sub-assemblies, to the set-up of the numerous different types and flavors of loadcases, there's one thing in common: The modular management of the model at each phase of its lifecycle. At early phases, modules are as small as CAD parts. Later, modules become functional sub-assemblies which, for crash and safety loadcases, are handled as include files. Although the modular way of work is the only reliable method to enable parallel work on different areas of the model, it increases the“administration cost” during the simulation preparation, as the pool of different modules (be they parts or include files) needs to be consumed by higher level structures in a way that facilitates data reuse and enables traceability throughout the complete digital thread of a simulation model.  BETA CAE Systems' Suite of applications addresses these challenges during model build and loadcase set-up with its Modular Model and Run Management solutions, that facilitate the handling of the different model and loadcase variants in a way that maximizes data reuse and enables traceability from part to simulation run, while mitigating the “administration cost” with the extensive use of templates. From the population of CAE subsystems based on the CAD structure, to the definition of different subsystem variants, vehicle configurations and loadcases, templates act as recipes that hold the instructions on which ingredients to use and how, in order to complete each given task.  This work discusses the definition and use of templates during model build and loadcase set-up, focusing on three key phases of the simulation preparation: First, the CAD to CAE structure mapping during Subsystem definition from PDM/PLM structures. Second, the handling of Subsystem variants in the scope of the different vehicle configurations. Third, the handling of parametric include files for the definition of Loadcases. Insights are given on the methods used for the adaptation of the templates to the specifications of each model in hand and how these are finally interpreted into LS-DYNA keywords behind the scenes, by making use of parameters, transformations and ID management techniques.

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Irene Makropoulou
BETA CAE Systems

October 22, 2024 02:30 pm

Manage multi-disciplinary load cases in SDM: model setup and evaluation of results

SDM

Due to the continuously increasing demand in Computer Aided Engineering (CAE), it is essential for high efficiency and transparency to automate and standardize processes. In many cases, Simulation Data Management (SDM) software is used for this purpose.   To achieve all mechanical target values of a product, there are several standard disciplines in the field of CAE, such as crash, Noise Vibration Harshness (NVH) or fatigue. Assembly, solving and postprocessing for these disciplines can differ greatly from one another. For this reason, it is best practice in many companies to carry out the optimization of a model in each discipline separately and to compare the results and structural adjustments with other disciplines at regular intervals. This approach can lead to two disadvantages:   Firstly, this results in redundant work. Model adjustments successful for one discipline must be redone in other disciplines later on. Secondly, deterioration in other disciplines may be discovered late: Model modifications that produce positive results for one discipline can have a negative impact on the results in other disciplines. This can lead to short-term changes of plans, postponements, or additional costs for optimizations.   With the help of a base model and SDM, several disciplines can be covered based on a single source of truth. The basic approach is not to work directly on the solver specific files, but on the base model itself. All discipline and solver specific files are generated from this file via SDM automatically. As an example, the two disciplines crash and NVH are considered in this paper. LS-Dyna is used as solver for both disciplines.   There are several criteria that must be met to successfully carry out multidisciplinary variant creation and result evaluation:   A complete database for all discipline-specific information, such as load case definitions or connection configuration is essential. Furthermore, a flexible and simple selection of the load cases is needed. It is also crucial to have an automatic process flow from the creation of the include to the finished report. This report must be designed according to the discipline-specific load case. A clear overview of all created variants is as important as a dynamic variant comparison of the results for each discipline.   The SDM software SCALE.sdm fulfills all these points, which is why it is used as the basis for this paper. So far SCALE.sdm is used by users in the industry like in the best practice example mentioned above: For each discipline there is a separate variant tree that is considered independently. By customizing specific key features such as an automatic creation of the include- and inter-include-connections, it is now possible to display all disciplines together with a single variant tree.   This approach makes it possible to avoid the above-mentioned disadvantages of the separate discipline approach: All the desired disciplines can now be covered by a single model modification, allowing the user to work effectively on structural optimizations while minimizing resources.

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Andreas Lohbrunner
SCALEsdm. US. Corp.

October 22, 2024 02:30 pm

Preload of Rotorcraft Blade for Impact Simulation

Aerospace Structure Impact and Dynamics I 

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Armando De Abreu

October 22, 2024 02:30 pm

Hans - Human Body Model: EnHansments

Human Body Models

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Alexander Gromer

October 22, 2024 02:30 pm

Recent advancements in material models

Material and Constitutive Modelling I

This contribution will deal with the latest developments in the field of material models in LS-DYNA. This includes completely new methods as well as extensions and improvements to existing models. The range of materials concerned includes metals, foams, composites, plastics, honeycombs, glass, adhesives, damage and failure models, and others. The new developments are aimed at improving prediction quality, robustness, performance, and user-friendliness. Examples will be used to illustrate the new features.

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Tobias Erhart
Dynamore, an Ansys Company

October 22, 2024 02:55 pm

Break

October 22, 2024 03:10 pm

Advancing Battery Safety Through Multi-Physics Modeling: From Experimental Data to Validated Simulation Models

Battery/Electric Vehicle

The rapid advancement of battery technology has driven the demand for advanced tools for a comprehensive understanding of battery cell behavior. This contribution proposes a holistic approach to generate digital twins of battery cells via coupled electro-thermo-mechanical modeling techniques within LS-DYNA. These models serve as precise representations of real-world battery cells, contributing to the development of efficient and secure battery systems.

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Martin Schwab
4a engineering GmbH

October 22, 2024 03:10 pm

Topology Optimization for Giga-Casting Design in Automotive Bodies Using LS-TASC & LS-DYNA

Machine Learning

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Akshay Kulkarni

October 22, 2024 03:10 pm

Modeling the Sloshing Phenomena of Fuel using LS-DYNA

Multiphysics Modeling

The sloshing phenomena is defined as the movement of a free fluid in a space or tank. Sloshing of fuel in a tank of an aircraft can cause dynamic disturbances that can affect the functionality of the operational system. This work examines two industrial real-life sloshing problems. The first example is the sloshing of fuel in a satellite tank. This can arise from the operational maneuvers of the satellite, which in turn can cause significant inertial forces that may lead to the decrease in performance of the satellite even up to the point of control loss. Another example concerns the slag liquids that may accumulate during the combustion process and acceleration phase of the rocket. These liquids can undergo sloshing which may narrow the nozzle opening and affect the motor performance and mission success. This work presents the attempt to model these sloshing phenomena using the most appropriate LS-DYNA solver. An overview of the available FSI solvers are presented and test cases are done in order to define the most appropriate way to model these real industrial sloshing problems.

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Yoav Lev
Rafael ltd

October 22, 2024 03:10 pm

Certification by Analysis: A discussion of solver requirements

Simulation Methods II

In recent years the fidelity of finite element models in structural mechanics has reached a remarkable quality and level of predictiveness. Hence, the question arises, if these models could even be more than the digital twin during product development: Could they be also used for homologation and certification of the corresponding products through the respective authorities or regulators as well? This idea is often referred to Certification by Analysis (CbA) or Virtual Testing (VT). It should be noted that in different industries various steps towards these goals are already taken.   The respective virtual testing procedures (including certification and homologation by regulators) require additional attention: Method development for solver enhancements needs to ensure data as well as IP protection of all stakeholders and provide measures to prevent data manipulation possibilities before homologation and market launch of the product. There are various technical as well as legal aspects to the whole process. But it needs to be emphasized that one key ingredient will be the ability of the solver to protect and safeguard input and output data while at the same time allow for traceability and transparency through fingerprinting technology when it comes to data sources like i.e. material properties, geometrical data, solver settings like version, solution method and contact parameters. Clearly, these requirements can only be met by new solver enhancements.   The present talk will target the big picture of CbA, show the route to achieve some of the most pressing issues and showcase a proposal for a first step into new solve features. This approach will be exemplified by the new Euro NCAP Virtual Far Side Simulation & Assessment regulation for occupant safety.

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Andre Haufe
DYNAmore / An Ansys Company

October 22, 2024 03:35 pm

Coupled Mechanical-Electrical-Thermal Behavior of Batteries: Experimental and Numerical Analysis

Battery/Electric Vehicle

With the increasing popularity of electric automotive vehicles, electric vertical take-off and landing (eVTOL) aircraft, and commercial drones, there is a subsequent increase in the need to better understand and predict the mechanical behavior of batteries during crash and impact events. A plasticity model of the cylindrical metal casing of commercially available batteries is developed through mechanical testing. The plasticity model is then validated by simulating the mechanical tests with LS-DYNA, which is then used to simulate crush tests on full batteries to determine the mechanical response of the inner battery components. Future work includes using LS-DYNA to accurately predict the coupled mechanical, electrical, and thermal response of batteries to prevent unwanted battery ignition during vehicle and aircraft crashes.

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Nathan Spulak
The University of Alabama in Huntsville

October 22, 2024 03:35 pm

Parametric ROM technology for fast optimization of Crash Problems

Machine Learning

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Sridhar Bijjala

October 22, 2024 03:35 pm

Simulating Safe Landing : A Deep Dive into Parachute Inflation and Float with LS-DYNA

Multiphysics Modelling 

Parachutes for aerospace application is a new research area in the current era of space science. The scope of our project includes parachute design and inflation techniques. The current research project focuses on the following application areas: ● Parachutes for Re-entry Capsule ● RLV Parachutes Parachutes are used as aerodynamic decelerators in airdrop systems, so inflation is a significant fluid-structure interaction (FSI) phenomenon. New patterns of parachutes are constantly being developed and tested for airdrop systems but this research into parachute inflation is heavily reliant on historical experimental data. Till now, no parachute inflation model that is not based on this experimental data was developed. Material and instrumentation have changed significantly since the early experimental testing, yet the methods to develop the parachutes can still be traced to the same techniques used over ninety years ago. Rapid development of computational technology and modern computational mechanics combined with numerical simulation techniques have become more widespread in parachute research field and would enable us to develop the parachutes that are more optimized. Simulating the landing of a vehicle on water using LS-DYNA is a complex task that involves the interaction between the fluid (water) and the structure of the vehicle. This type of simulation is crucial for vehicles designed to land on water. The process typically involves several steps and requires specialized techniques within LS-DYNA.

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Chandra Sekhar Kattamuri
CADFEM India

October 22, 2024 03:35 pm

Fluid Slosh Behavior For Crashworthiness A Modeling Approach Validated With Experimental Data

Simulation Methods II

October 22, 2024 04:00 pm

Exploring Ansys LS-DYNA's Battery Modeling Capabilities

Battery/Electric Vehicle

Over the past decade, considerable advances have been made on battery safety models but achieving predictive accuracy across a wide range of conditions continues to be extremely difficult. From a numerical perspective, the obstacles are numerous.   Multiple physics can potentially be involved and interact with one another, electrochemistry, thermal, mechanical, fluid dynamics and so forth. The question of modeling scale also invariably arises. Is it reasonable to imagine a numerical model resolved at the micro scale being later used in a macro model such as car crash simulation?   LS-DYNA was initially approached by several actors in the automotive industry in order to develop simulation tools that would eventually allow an engineer to design a Multiphysics model for a battery pack or module that could be run as a stand-alone simulation or, later on, be included in different crash simulations at a reasonable cost. Several developments have emerged from this original ask, that are present in LS-DYNA and available to all users and engineers interested in the broad aspect of battery simulation.   In this paper, modelling techniques for the mechanical aspect of battery simulation (eg material laws), will be discussed. The BatMac module, a part of the LS-DYNA EM solver used to capture internal and external shorts will be introduced up to and including the initial heat generation, thermal expansion, and thermal runaway modelling. Validation results and workflow examples will be given. Finally, topics that are of contemporary interest to battery simulations such as busbar thermal expansion, swelling, or venting will be discussed.

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inaki Caldichoury
ansys

October 22, 2024 04:00 pm

From automatic event detection to automatic cause correlation

Machine Learning

N. Abdelhady1, D. Borsotto1, V. Krishnappa1, K. Schreiner1, C.-A. Thole1, T. Weinert1 1SIDACT GmbH Reaching and fulfilling several design and crash criteria during the development process is what makes the engineer adapt and redesign the simulation model over and over again. Ideally resulting in new simulation runs with in best case improved performance, matching the intention of the applied changes. For the more demanding case of unforeseen results which do not necessarily fit to the expectations of the actual changes, machine learning methods and a workflow are being introduced here, which allow to identify the root cause of this behavior.  In a first instance every new simulation run is being added into an analysis database, which is continuously being used to compare new simulations against. Previous studies have already shown that this process can assist the engineer in automatically highlighting new behavior and pin pointing the engineer to the regions of interest. Rather than only highlighting the new behavior now a second phase is being triggered additionally.  In this second phase the previously detected event is being isolated and analyzed against the gathered data of the development history. The analysis methods used are based up on the Principal Component Analysis, a reduced order modelling technique. This allows not only identifying structures in the data but also correlating deformation patterns against each other. Especially the latter one is of interest for an automated process, as it allows automatically detecting and suggesting possible root causes to the engineer. As an outcome of this process the engineer receives a list of correlating parts, so that he can focus on deriving a better engineering solution to achieve a deterministic behavior, rather than searching for the root cause of the event.  To provide additional information about the type of cause, as for example failure or buckling, the identified parts are also forwarded to a classification prototype. This type of classification shall assist the engineer in deriving a possible design adaptation.

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Dominik Borsotto
SIDACT GmbH

October 22, 2024 04:00 pm

Enhancing FSI Simulations in LS-DYNA: Implementing Immersed Interface Techniques in the Incompressible CFD Solver

Multiphysics Modeling

This paper focuses on implementing immersed interface techniques within the Incompressible CFD (ICFD) solver in LS-DYNA. For Fluid-Structure Interaction (FSI) simulations, immersed methods offer several advantages: they simplify the pre-processing stage, prevent large mesh distortions due to structural motion, and provide more robustness in scenarios involving complex contacts. However, these methods sacrifice accuracy in near-wall regions, suggesting that a hybrid approach between body-fitted and immersed methods could be beneficial in some cases. This work discusses two methods: the Resistive Immersed Implicit Surfaces (RIIS) method [1] and a method based on a new set of discontinuous finite element functions [2]. The basics of these methods will be presented, along with considerations for setting up a model in LS-DYNA, including pre- and post-processing.  [1] Fernandez MA, Gerbeau JF, Martin V (2008) Numerical simulation of blood flows through a porous interface. ESAIM: Mathematical Modelling and Numerical Analysis 42(06): 961-990. [2] R. Zorrilla, R. Rossi, R. Wüchner, E. Oñate, An embedded Finite Element framework for the resolution of strongly coupled Fluid-Structure Interaction problems. Application to volumetric and membrane-like structures, Computer Methods in Applied Mechanics and Engineering, Volume 368, 2020, 113179.

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Facundo Del Pin
Ansys

October 22, 2024 04:00 pm

Modular Contact: A new approach to contact in LS-DYNA

Simulation Methods II

The "Modular Contact" is a new implementation of contact algorithms in LS-DYNA. We will give a short overview of the fundamental ideas behind it and how it tries to achieve its main goals: a more uniform implementation between different contact options and improved (parallel) performance by better harnessing of modern hardware and improved MPI communication. The performance will be demonstrated on large models and put in comparison to the well-established, existing algorithms in LS-DYNA.

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Albert Ziegenhagel
Ansys

October 22, 2024 04:25 pm

Modeling Battery Safety under Penetration Loads Using LS-DYNA

Battery/Electric Vehicle

The safety of battery systems in electric vehicles (EVs) and portable electronics under impact or penetration is critical. Traditional modeling methods, relying on simplified approaches, fall short in capturing complex interactions and dynamic behaviors. Advanced simulation techniques using LS-DYNA offer more accurate predictions of battery responses to penetration loads. This abstract outlines recent methodologies employing LS-DYNA for high-fidelity modeling of battery components and protective measures. Innovations include sophisticated material models for electrodes, electrolytes, separators, and structural packaging. These advancements align with standards like SAE J264, ensuring battery safety and reliability, thereby supporting the adoption of electric mobility and renewable energy technologies.

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Satish Kumar Meenakshisundaram

October 22, 2024 04:25 pm

LS-OPT Pro: Status and Outlook

Machine Learning

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NIELEN STANDER
Ansys LST

October 22, 2024 04:25 pm

New porous media model for high-speed flows and EnSight-specific postprocessing output in the dual-CESE solver in LS-DYNA

Multiphysics Modelling

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Grant Cook

October 22, 2024 04:25 pm

New Advances in the Discrete Element Method (DEM)

Simulation Methods II

In the last three decades, DEM (Discrete Element Method) has been extensively developed and applied to solve many geotechnical and petroleum engineering problems. Another approach is developed to account for the elastic and brittle behavior of materials. The method has been successfully implemented in the LS-DYNA to study cementitious, sintered, and rock materials such as concrete, fibers, rocks, etc.  Explosives with the combination of rock, concrete, and other brittle materials are simulated using LS-DYNA and studied extensively by researchers. In such cases, the volume of the fragments and number of fragments would be beneficial to the researcher. To assess this, we have developed a system that computes the number of fragments, fragment volume, and number of bond links associated with the DEM particles. Users have the option of outputting the results described above, depending on the user control card by using *DATABASE_DEFRAGMENT.  Additionally, DEM has been extended to simulate the likes of intumescent material through new keyword *DEFINE_DE_TEMP. The DEM formulation has been extended to include the temperature effect on the radius of DEM particles. The method takes the user’s temperature with several inputs and expands the radius of the particle based on the temperature and coefficient of thermal expansion. With recent improvements, the DEM can be thermally coupled with the Finite Element Method (FEM), and particles can change size in response to temperature changes in the DEM. The new improvements allow for the simulation of complex thermal behavior in a variety of real-world scenarios, like soil interaction with a blasting battery, a heated container containing discrete material etc. Users can activate thermal conductivity of the DEM by providing the required data in the DEFINE_DE_BY_PART, CONTROL_DEM, and DEFINE_DE_TO_SURFACE_COUPLING. The LS-DYNA/MPP decomposes the problem once based on its initial geometry. For good MPP parallel efficiency, the deformation of the geometry should not be too large to keep reasonable ratio between computation and communication time. However, most DEM problems are dealing with granular flow which involve mixing and large relative displacement between particles. The parallel efficiency degrades due to increasing data communication. A re-decomposition algorithm supports DEM features which can reduce computing costs by 30%. This algorithm would rearrange the grouping of the particles, thus avoiding the search for neighbors that are far away from the group. A Galerkin meshfree method can generate shape function without the need of element or mesh, allowing it to provide a quality solution for large deformation problems such as fragmentation, cracks, material separation etc. The shape function in the meshfree method is rational function with complexity and because of this the domain integration scheme becomes challenging. Over the last 2 decades, several integration schemes were developed to obtain a computationally efficient and stable solution. Few methods can resolve the stability related issues and the efficiency; However, the meshfree methods are still computationally expensive due to the requirement of the higher support size.  To address this issue a novel method, namely Expedited Galerkin Meshfree Method (EGMM) is developed. The method employs a nodal integration with a unique stabilization scheme to stabilize the solution at lower support size. The method only needed a minimum evaluation point and does not require direct second order derivative of the shape function. The method achieves its objectives by stabilizing the Galerkin solution with minimum computational cost. The resulting method conserves the linear momentum and the total energy. The contact between the two bodies or the particles can be easily implemented by integrating with the Discrete Element Method. Overall, the simulation result demonstrates that the method is stable and works effectively for the various types of materials. The user can define this model similar to the solids by generating solid and using *SOLID_EGMM. Numerous material behaviors are taken into consideration by using the constitutive model, which can be defined by *MAT_

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Mohammed Mujtaba Atif
Ansys

October 22, 2024 04:50 pm

Scaling from Battery Cell to Electric Vehicle (EV) Crash - A Case Study from Full Vehicle Teardown

Battery/Electric Vehicle

As EVs become more mainstream safety concerns have been paramount for OEMs, consumers and regulators. Owing to the risk of thermal runaway in an EV crash incident, a full Multiphysics battery analysis is required to capture the mechanical deformation that triggers internal shorting and thermal runaway.  This is helpful in knowing the mechanical design limits and designing vehicles with good crashworthiness while balancing the need to lightweight EVs as car companies strive for better range.   Ansys developed a simulation workflow from battery cell to vehicle level (in partnership with universities and industry test labs) to validate key pieces using physical test data from a 26Ah automotive pouch cell.  LS-DYNA models were calibrated and subsequently validated against cell experimental data. Multiphysics models that captured a battery cell's electrical, mechanical and thermal behaviors were then to used to scale up in a proof-of-concept simulation of full vehicle crash. 

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Vidyu Challa, PhD
Ansys

October 22, 2024 04:50 pm

Multiphysics Analysis of Automotive Components for Product Portfolio Optimization

Simulation Methods II

In this study, the pillars A, B and C from the Body-in-White (BIW) of a pickup passenger vehicle were considered, and the steels used for these components were identified based on the A2MAC1 platform, the SAEJ2947 standard, and state-of-the-art literature. Subsequently, these steels were compared with the client's product portfolio to propose a steel that meets the characteristics demanded by the automotive market for each of the components considered in the BIW. Next, the performance of each of the three pillars with these steels was validated and compared through crashworthiness simulations using Finite Element Analysis (FEA) with ANSYS LS-DYNA software. These simulations modeled the behavior of the pillars on side impact tests, with meshed parts based on the 2014 Chevrolet Silverado 1500 FEA model from the CCSA of the George Mason University. The impact speed was based on the Oblique pole side impact testing protocol from Euro NCAP; the time simulation was based on the Side impact Crashworthiness Evaluation 2.0 Rating Guidelines from the IIHS. To compare materials’ behavior, different curves were defined for each case. The tested materials were evaluated by comparing internal energy and displacement on each of the three pillars. Finally, results regarding the behavior of the different materials were discussed.

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Santiago Torres
Universidad de Monterrey

October 22, 2024 04:50 pm

Study of Vehicle Aerodynamics with the ICFD Solver and its Application to the Quarkus P3 Pikes Peak Version

Multiphysics Modelling

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M. Le Garrec

October 22, 2024 04:50 pm

Fully Transient Vehicle Crash Predictions powered by SimAI

Machine Learning

October 22, 2024 05:30 pm

Reception

October 23, 2024 07:30 am

Exhibits Open

Exhibition

October 23, 2024 07:30 am

Continental Breakfast

Meals

Walk the exhibition space to grab your quick breakfast before general session.

October 23, 2024 07:30 am

Registration

Registration Desk Open

October 23, 2024 07:30 am

HPE | AMD Invitation-Only Roundtable

Next gen CAE: Setting a new standard for product development with HPE and AMD 

To effectively support and scale their Ansys applications, manufacturers must enhance engineering productivity, become more data-driven, meet sustainability goals, scale flexibly, and increase profit margins.  Hewlett Packard Enterprise and AMD have teamed up with Ansys, the premier provider of CAE software, to help revolutionize product design. Our next-generation CAE solutions deliver virtually unlimited capacity and industry-specific tools to speed up design cycles and lower total cost of ownership (TCO). 

Join us to explore how you can optimize your CAE infrastructure for all your Ansys applications. Bring your questions and let’s shape the future of engineering together! 

October 23, 2024 07:30 am

TotalCAE Invitation-Only Roundtable

The Impact of AI/ML in the Product Development Process 

Artificial intelligence (AI) and machine learning (ML) have emerged as a potential transformative force in product development. This round table will explore the pivotal role of AI and ML in shaping the future of product design and optimization. We will delve into how these technologies streamline the speed and quality of the development process, AI/ML challenges and limitations that we can work together on addressing, and how to get started in testing these technologies. 

October 23, 2024 08:00 am

Advancing Transportation and Road Safety: GMU's Research Activities Using LS-DYNA Simulation

General Session

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Rudolf Reichert
George Mason University

October 23, 2024 08:30 am

Optimization of Diastolic Material Parameters: Use of a Shape-Based Objective Function in Conjunction with a Feasibility Classifier

Biomedical/Healthcare I

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Mark Ratcliffe
UCSF

October 23, 2024 08:30 am

Modelling thick-walled aluminium extrusions in side-crash applications

Crash II

A critical consideration in the design of protective structures for electric vehicles is their energy absorption capacity. The development of lightweight structures is essential, as the range and weight of electric vehicles are intrinsically linked. High-strength aluminium structures are frequently used due to their exceptional strength-to-weight ratio and excellent mouldability. Aluminium alloys within the 6xxx series are of significant interest attributable to satisfactory performances in energy absorption applications when subjected to severe mechanical loads.  Traditionally, in the automotive sector, extruded profiles are modelled using shell elements, which are based on the plane stress assumption. This approach is generally accepted for thin-walled profiles.  In contrast, shell elements inadequately describe the mechanical behaviour of complex thick-walled structures. As the wall thickness becomes significant in relation to their length, stresses and deformations appear in the thickness direction, which could lead to the formation of out-of-plane shear cracks.  Therefore, the use of shell elements appears unsuitable for this application. Instead, refined solid element meshes and fracture models are used in these models.   In this study, the mechanical behaviour of a thick-walled multi-chamber aluminium extrusion has been investigated. Different element technologies and materials models have been evaluated based on dedicated material and component tests, trying to find a balance between accuracy and computational cost.

October 23, 2024 08:30 am

Study on Impact Loading Reduction Performance of "Origami Hat"

Drop/Impact Dynamics

With the enforcement of the revised Road Traffic Act, wearing helmets has become a mandatory effort for all cyclists since April 1, 2023 in Japan. However, there are still many people who do not wear helmets. Therefore, we considered developing a foldable helmet that can be easily carried by applying the concept of origami engineering. Origami engineering is a research field proposed with the aim of developing lightweight, high-strength structural components based on the idea of origami, a traditional Japanese craft in which various shapes are created by folding paper-like materials. Under the same conditions of the safety test for industrial helmets, a 5 kg striker was dropped from a height of 1.0 m onto a dummy head wearing the hat, and the impact load received by the dummy head was computed in the simulation. As a result, it was confirmed that it was possible to reduce the impact load by devising the proper material properties and folding shape.

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Sunao Tokura
Tokura Simulation Research Corporation

October 23, 2024 08:30 am

Ansys Forming - The New GUI for Forming Simulations with LS-DYNA: An Overview and Outlook

Forming II

Ansys Forming is the new graphical user interface (GUI) for sheet metal forming simulations with LS-DYNA. While LS-DYNA is renowned for its precision in sheet metal forming simulations, its complexity often necessitated extensive expertise. Ansys Forming addresses this challenge by providing a user-friendly GUI that guides users through the setup process seamlessly. Developed by the same team behind the solver, Ansys Forming ensures perfect integration with LS-DYNA, facilitating all finite element (FE) related tasks. It is designed to meet the needs of method engineers, making the process more intuitive and efficient. Users can easily define operations, set up tools and their kinematics, specify the blank and material properties, select trim lines, and configure flanging operations. Additionally, determining the measurement station with all pilots and clamps to accurately calculate springback is straightforward. The analysis features of Ansys Forming empower users to thoroughly evaluate the part and process. The GUI provides tools for visualizing tool movements, formability diagrams, wrinkle analysis, surface analysis for class A panels, real sheet thickness, and contact gaps. Assessing the formability of the part and displaying springback relative to a reference part is essential for tool springback compensation. This presentation will offer an overview of Ansys Forming's functionalities and a perspective on future developments.

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Chris Robinson
Ansys

October 23, 2024 08:30 am

Application of Trimmed Solid in IGA to Aluminum Diecast Part Analysis

IGA I

To reduce the impact of automobiles on the global environment, there is an urgent need for automotive OEMs and other related companies to take initiatives such as carbon neutrality and resource circulation. As part of the use of sustainable materials, each company is considering the adoption of large-scale aluminum diecast (ALDC) parts for the purpose of integrating components and enhancing the recycling rate. ALDC could be applied to parts for which safety performance against car crashes is required. For the design of such parts, their performance needs to be predicted through crash analysis. Large ALDC parts usually contain thick walls and complex geometry, and tetrahedral elements are often used to model such parts in Finite Element Analysis (FEA). While tetrahedral elements are relatively easy to use for creating a model, they generally have poor analytical accuracy, especially when reproducing bending deformations. To achieve sufficient accuracy, models need to be subdivided adequately in the thickness direction as well as in the in-plane direction, or higher-order elements need to be used. Consequently, computational time could increase significantly compared to conventional steel sheet parts that use shell elements, due to an increase in the number of solid elements or a reduction in the time-step size. This increase in computational time hinders efficient vehicle development. One of the methods that can address the issue is Isogeometric analysis (IGA). IGA is an analysis method that employs high-order spline functions as basis functions, similar to CAD. Because IGA achieves higher continuity than C^{p-1} even at element boundaries, it provides good accuracy even with coarser elements. Additionally, analysis can be performed with larger time step sizes compared to the FEA. In bending analysis, IGA only requires one solid element through the thickness, resulting in significant computational time reduction compared to tetrahedral elements. However, a drawback of IGA is the difficulty of solid model creation, making it very challenging and time-consuming to create large and complex ALDC part models. In such circumstances, the development of trimmed solids for IGA is in progress. The trimmed solid is one of the embedded analysis methods that do not require the creation of boundary-fitted meshes strictly defining the geometry's boundaries. Consequently, the model creation is much easier than with boundary-fitted solids used in conventional IGA. Considering both model creation time and analysis time, the trimmed solids are expected to have a significant impact in crash analysis. However, its application in industry is still limited, and to the best of the author's knowledge, there are no examples yet of its application in vehicle crash analysis. In this presentation, we will introduce some application examples of trimmed solids for ALDC parts analyses. First, a simple bending analysis was conducted to evaluate the load response and confirmed its accuracy. Subsequently, more analyses were performed on complex parts. The results confirmed that computational time was significantly reduced compared to conventional FEA, while maintaining accuracy. Additionally, we will discuss some remaining issues during the presentation.

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Tadashi Naito
Honda Motor Co., Ltd.

October 23, 2024 08:30 am

Advancements in Humanetics' FE Models

Occupant and Pedestrian Safety II

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Zhaoying Feng

October 23, 2024 08:30 am

Digital Transformation and MBSE Workshop

Join us for an in-person hands-on workshop as we aim to explore solutions for digital transformation initiatives. Discover the tools to optimize processes faster with greater efficiency, and be inspired to design, build, and work in new ways. Gain insight into how digital transformation challenges are being addressed with innovative solutions by thought leaders and industry experts. Attendees are asked to bring a laptop for the hands-on portion of the Workshop.​

8:30 AM - 8:45 AM Welcome/Opening  
8:45 AM – 9:15 AM Industry guest speaker 
9:15 AM – 10:10 AM MBSE Hands-on workshop - part 1 
10:10 AM - 10:30 AM Break
10:30 AM - 12:30 PM MBSE Hands-on workshop - part 2 
12:30 PM - 1:00 PM Lunch
1:00 PM - 1:30 PM MBSE Hands-on workshop - closing

October 23, 2024 08:30 am

Digital Safety Workshop

Join us and the industry leaders from automotive and semiconductors in this in-person hands-on technical workshop focused on model-based safety analysis. We recommend the participants who plan to join bring their laptops for the hands-on experience.

8:30 AM – 8:45 AM Welcome/Opening  
8:45 AM - 9:40 AM Safety Product and the Collaboration Platform 
9:40 AM - 10:10 AM Guest speaker - CS Group 
10:10 AM - 10:30 AM Break 
10:30 AM - 12:00 PM Hands-On Workshop for DSM and Safety Cases 
12:00 PM - 1:15 PM Lunch 
1:15 PM - 2:30 PM Hands-On Workshop for Digital Engineering at Ansys 
2:30 PM - 3:00 PM Break 
3:00 PM - 3:30 PM AI for safety and cybersecurity analysis 
3:30 PM - 4:50 PM Safety of AI 
4:50 PM - 5:00 PM Wrap Up & Closing 

October 23, 2024 08:30 am

Embedded Software Workshop

Join us and the industry leaders from automotive and semiconductors in this in-person hands-on technical workshop focused on model-based safety analysis. We recommend the participants who plan to join bring their laptops for the hands-on experience.

8:30 AM – 8:45 AM Welcome/Opening  
8:45 AM - 10:10 AM Hands-On Workshop Part 1: Architecture and Design of Embedded Software 
10:10 AM - 10:30 AM Break 
10:30 AM - 11:00 AM Academic Guest Speaker (UNAQ): Adoption of SCADE in a Full Academic Program 
11:00 AM - 12:00 PM Hands-On Workshop Part 2: Software Implementation and Verification 
12:00 PM - 1:15 PM Lunch 
1:15 PM - 1:45 PM Hands-On Workshop Part 3: System / Software Integration 
1:45 PM - 2:30 PM From Fail-safe to Fail-operational: Model-Based Solutions for Automotive Embedded Controls of the Future 
2:30 PM - 3:00 PM Break 
3:00 PM - 4:00 PM Hands-On Workshop Bonus: Ansys Innovations with Scade One 
4:00 PM - 4:30 PM Wrap Up & Closing 

October 23, 2024 08:55 am

Design Evaluation of an Ortho-Chair for the Prevention and Relief of Lower Back Pain

Biomedical/Healthcare I

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M Sahul Hamid

October 23, 2024 08:55 am

Simulated Failure Limitations of Midwest guardrail System

Crash II

October 23, 2024 08:55 am

More than 40% cost reduction through drop test simulation with Ansys LS-DYNA

Drop/Impact Dynamics I

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Manfred Maurer

October 23, 2024 08:55 am

Die Hemming Simulation with Ansys Forming and LS-DYNA

Forming II

October 23, 2024 08:55 am

Evaluation of B-Pillar crush using IGA Shells

IGA I

Iso Geometric Analysis (IGA) uses higher order and higher continuity splines to represent the geometry and the solution field. This enables the use of more accurate geometry representation, higher solution accuracy and a larger timestep size compared to traditional Finite Element Method (FEM).  In this study, IGA shells are used to simulate the B-Pillar crush and the results are compared with FE mesh and physical test results. Both the B-Pillar displacement as well as the platen force are predicted reasonably accurately by the IGA model. Since all legacy material models, contact and connection techniques can be used with IGA without any change, a Hybrid modelling approach can be used for vehicle crash models where the IGA shells can be included for critical parts where higher accuracy and better crush prediction is desired.

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Amruta Raut
Stellantis

October 23, 2024 08:55 am

Enhancing Vehicle Safety Assessments through Advanced Virtual Testing Crashworthiness with the aid of ANSA and META

Occupant/Pedestrian Safety II

The automotive industry is continually evolving to meet stringent safety standards and enhance occupant protection in crash scenarios. With Euro NCAP supplementing far-side impact testing with Virtual Testing Crashworthiness (VTC) starting in 2024, real tests and CAE simulations come closer more than ever. The VTC protocol mandates the use of simulation and physical test data to robustly evaluate far-side impact protection, requiring detailed compliance with validation and quality criteria, as well as specific data formatting for submission. Consequently apart from far-side more protocols will be implemented in the virtual testing raising more challenges to the safety engineers. As a result there is an increasing need for efficient tools that streamline the assessment process offering ‘know how’ of the different protocols and simultaneously minimize the human interaction with the aid of automation. This paper introduces the solutions that BETA CAE has come up with, in order to bridge CAE with real testing covering all the current but also the future needs of VTC. In ANSA the pre-processor a new tool has been introduced that automates the ATD/HBM positioning process following the specifications of each protocol or utilizing experimental data coming either from posture landmarks or scanned STL meshes. Along with the already known in the market, seat positioning, seatbelt and impactor tools form a complete suite to ensure an easy and proper preparation of the model for ANSYS LS-DYNA safety simulations. Additionally, an innovative software tool has been integrated within META, BETA CAE Systems post-processor, designed to meet and exceed the requirements of the Euro NCAP VTC protocol. The tool offers comprehensive functionalities to facilitate the evaluation process, ensuring accuracy, efficiency, and compliance. Key features of the tool include the ability to read and process all necessary LS-DYNA simulation and physical test results, and export the data in the ISOMME format with precise adherence to protocol requirements, ready to be uploaded to the Euro NCAP website. Additionally, the tool performs pre-assessment in the same manner as Euro NCAP, allowing automotive manufacturers to know their potential rating before submitting the results officially. This pre-assessment ensures that manufacturers can refine their designs to achieve the desired safety ratings. By automating the critical aspects explained above, the aforementioned tools significantly reduce the time and effort required for vehicle safety assessments. They ensure that automotive manufacturers can efficiently comply with the latest Euro NCAP standards and beyond, ultimately contributing to the development of safer vehicles.

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Thanassis Fokylidis
BETA CAE Systems SA

October 23, 2024 09:20 am

Leveraging Graph Neural Networks for Surrogate Model Development in Automotive Crash Simulations

Crash II

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Matt Nierman

October 23, 2024 09:20 am

Accidental Fuel Drop on Spent Fuel Pool Storage Racks

Drop/Impact Dynamics I

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Ragunath Sankaranarayanan

October 23, 2024 09:20 am

Simulation workflow for Transcatheter Aortic Valve Replacements: From crimp and deployment to fluid-structure interaction

Biomedical/Healthcare I

The design of a stent frame for transcatheter valve replacements is a challenging task as treatment preparation and deployment have an influence on the final shape and performance of the device. Moreover, a complicated fluid-structure interaction load case is required to assure optimal performance of the valve and to predict stresses and strains in the frame for fatigue life assessment. Typically, one distinguishes between balloon-expandable frame designs mostly made of stainless steel or self-expandable frame designs made of nitinol as shape memory alloy. The focus of this contribution is on self-expandable frames and all simulations are based on a mockup geometry of the Evolute-R System of Medtronic, which is frequently used in literature. The goal of this presentation is to set up these simulations such that they can be connected in an automated workflow. Simulation steps include a crimping simulation of the stent frame into a delivery capsule as well as a micro catheter insertion simulation into the anatomy to determine a good initial position for the deployment simulation of the device into the anatomy. After the device is properly deployed, fluid-structure interaction simulations are carried out to assess the performance of the valve. With such a workflow, these simulations can be repeated at different implant depths to find a position where the performance of the valve is optimized or even repeat the simulations for other anatomies. This will allow design engineers in industry to quickly assess design ideas under real-life loading conditions. A simplified user interface of the workflow will democratize these complicated simulations to make them available to clinicians to check the optimal sizing and positioning of the device.

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Nils Karajan
DYNAmore, An Ansys Company

October 23, 2024 09:20 am

A systematic study on Ansys Forming performance

Forming II

Mesh adaptivity refines the blank mesh as needed in stamping simulations. Users do not need to anticipate where a dense mesh will be required. Despite its universal use, it demands significant effort due to serialization and the need to carry a dense mesh through subsequent iterations. In-Core adaptivity and Mesh fusion assist the solver in conserving effort, thereby enhancing performance. This paper will demonstrate best practices for utilizing In-Core adaptivity and Mesh fusion in Ansys Forming through practical cases. In addition, for different model, we should find an optimum number of CPUs to run the job. Beyond this number, the scalability will not see any obvious improvements.

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Kang Shen
Ansys

October 23, 2024 09:20 am

Recent Enhancements and Studies of Isogeometric Shells in LS-DYNA

IGA I

Isogeometric Analysis (IGA) [1] is a Finite Element Analysis (FEA) technology that uses spline basis functions known from Computer Aided Design (CAD) to describe the geometry and the solution field. Employing such spline basis functions with higher order and higher continuity may yield several advantages such as an easier transition from CAD to analysis, a more accurate geometry description, smooth solution fields or a larger time step in explicit analysis. In fact, only the higher-continuity property of splines enables the concept of trimming (ubiquitous in CAD) to be used in explicit analysis with a feasible time step size [2].  Over the last years, the trimmed IGA shell capabilities of LS-DYNA were consistently enhanced and reached a high level of maturity [3,4] as demonstrated in a recent study by Bauer et al. [5]. In that study, a Body in White was modeled with hundreds of trimmed IGA shell components (using ANSA [6]) and successfully implemented in hybrid IGA/FEA full vehicle crash simulations.

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Lukas Leidinger
DYNAmore GmbH, an ANSYS company

October 23, 2024 09:20 am

Mitigating Risks at Bus Stops: A Study of the Effectiveness of Bollard Systems

Occupant/Pedestrian Safety II

All major metropolitan areas are served by a complex network of public bus transit services with thousands of transit stops, serving millions of passenger trips, including a large number of riders with wheelchairs or bicycles. The safety of bus network patrons and employees is critically important, especially while onboard transit vehicles and at transit stops. Although most metropolitan bus services have a good overall safety record, several bus stops are struck by motor vehicles each year. Fortunately, most of such incidents do not result in significant fatalities or major injuries. However, it is important to enhance the safety of bus stops through proactive measures to mitigate vehicle crash risks. These measures not only provide a safe space for passengers but also protect the bus stop shelters. This work considers the use of bollard systems to protect transit stops. The main objective of the study is to assess the effectiveness of a proposed interconnected multi-bollard design in protecting bus stop occupants from vehicular impacts.  An analysis was conducted to determine the efficacy of this system in stopping oncoming vehicles, and the potential effect of the crash on the driver. A detailed model of a 3-bollard system was developed in Ansys LS-DYNA. This model included the bollards, their underground support structures, and the rebars connecting the bollards. The bollard system was composed of 116 parts with a total of 443,799 elements. The bollard system model was merged with a detailed model of a 2007 Chevrolet Silverado, 4-door crew cab pickup truck. The vehicle model has 603 parts with 251,400 elements. The vehicle was simulated to impact the bollard system at speeds between 15 and 90 mph at angles ranging from 0 degrees (normal to the bollard system) and 90 degrees (parallel to the bollard system). Impacts were also made at various degrees of centeredness, with cases showing response from impact at the center of bumper, as well as at the edge of the bumper. With each case, vehicle velocity and acceleration were monitored using virtual accelerometers, placed in the vehicle to assess the effectiveness of the bollard to stop the vehicle and the potential of driver's injuries. Simulation results show that the bollard was able to stop a vehicle traveling normal to the bollard system, impacting the center of the bumper at speeds up to 45 mph. However, the vehicle would continue past the bollard system at higher speeds. The study also discusses the effect of the vehicle impacting the bollard system at different angles and at different off-center locations.

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Jonathan Lazatin
UNLV

October 23, 2024 09:45 am

Introducing J-SimRapid, A New Reduction Modelling Tool for Vehicle Crash Simulation

Crash II

Demands for ever increasing efficiency of automotive crash analysis have continued to rise in the drive to reduce automotive development costs. When major design changes are required to satisfy product performance late in the development process, significant cost and time are required to implement them. To alleviate this, automotive manufacturers have adopted the concept of "front-loading" to identify problems early-on in the development process. The earlier issues in the production phase can be identified, the more efficiently and effectively development can be performed. JSOL Corporation has developed a new method for modelling automotive body structures to simulate crash analysis in the early stage of design that employs Hughes-Liu beam elements with arbitrary cross-sectional geometry. Then JSOL Corporation has released a new modelling tool J-SimRapid that can easily create the reduction models. This tool enables front-loading crash safety analysis in the conceptual design phase. Furthermore, it can also reduce large-scale models in the detailed design phase. Consequently, J-SimRapid makes overall automotive design phases more efficient. In this presentation, the new model reduction method will be introduced along with examples of reduced model analysis by J-SimRapid.

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Shinya Hayashi
JSOL Corporation

October 23, 2024 09:45 am

Sequential drop test simulations through automated process in Workbench LS-DYNA

Drop/Impact Dynamics I

October 23, 2024 09:45 am

3D Drawbead Design and Mesh Regeneration in Ansys Forming

Forming II

In ANSYS FORMING, we have developed innovative techniques for predicting drawbead forces and generating 3D drawbead geometry to streamline the drawbead design process, which is crucial for controlling material flow in stamping processes. These tools include a drawbead profile generator, a simulator, and a 3D drawbead generator. The profile generator creates custom drawbead profiles based on sectional design parameters, while the simulator estimates restraint and uplift forces through a strip drawing test. The 3D drawbead generator automatically creates 3D drawbead meshes from single or multiple drawbead profiles for both closed and open beads, enabling accurate material flow estimation in 3D high-fidelity stamping simulations. In addition, we introduce an innovative surface mesh regeneration method based on adaptive quadtree refinement to address issues of distorted or skewed initial meshes. This method intelligently refines regions with complex features or high gradients that require higher resolution, while discretizing smoother areas with coarser elements, optimizing computational resources without sacrificing precision. Our approach also preserves original boundaries, ensuring the fidelity of simulation results. These advancements, validated through real-world examples, significantly enhance the design capabilities and modeling performance of ANSYS FORMING in stamping simulations.

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Xiaolong He
Ansys

October 23, 2024 09:45 am

Updates on trimmed IGA B-Spline Solids

IGA I

Recently, so-called trimmed Isogeometric B-Spline Solid elements have been introduced in LS-DYNA [1]. The numerical analysis methodology Isogeometric Analysis (IGA) dates to the paper by Hughes et al. [2] in 2005. While standard Finite Element Analysis (FEA) usually uses polynomial-based basis functions, IGA tends to use the same shape functions employed in the Computer Aided Design (CAD) environment for numerical analysis. This paper recalls the main ideas and concepts of the trimmed IGA B-spline solid finite elements in LS-DYNA and gives an update on the available capabilities. The current workflow of how to setup LS-DYNA models with these new types of elements will be introduced. Available methods of how to deal with boundary conditions, contact, connection modeling and refinement strategies will be shown, and some recommendations and best practices will be shared. A set of numerical studies will demonstrate the potential benefits of these new types of solid finite elements. The paper closes with a summary and an outlook of future development activities.   2 References  [1]  Hartmann, S., Leidinger, L., Bauer, F., Benson, D., Nagy, A., Li, L., Pigazzini, M., Nguyen, L.: "Trimmed IGA B-Spline Solids vs. Standard Tetrahedra Finite Elements", 14th European LS-DYNA Conference 2023, Baden-Baden, Germany. [2]  Hughes, T.J.R., Cottrell, J.A., Bazilevs, Y.: "Isogeometric Analysis: CAD, finite elements, NURBS, exact geometry, and mesh refinement", Computer Methods in Applied Mechanics and Engineering, Vol. 194, 2005, 4135-4195.

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Stefan Hartmann
Dynamore GmbH, an Ansys Company

October 23, 2024 09:45 am

Data preparation for the Euro NCAP far-side ISO18571 rating calculation with tools from the DYNAmore Eco System

Occupant/Pedestrian Safety II

In 2024 the Euro NCAP Virtual Testing far-side protocol was introduced with a monitoring phase. The protocol defines all the requirements in precise detail. To obtain an assessment for the virtual testing, the OEM needs to pass two validation load cases. The assessment is conducted using ISO18571 ratings. Euro NCAP is responsible for the ISO18571 rating calculations. The OEM must provide the simulation and test data in a predefined ISO-MME data format. If the ratings meet the defined criterion, the virtual testing assessment is deemed successful. This paper presents a straightforward workflow for preparing ISO-MME data, illustrated by a case study of a far-side test involving the open-source Yaris car and the DYNAmore WorldSID dummy model in LS-DYNA. The DYNAmore Eco System tool DM.binout2isomme is used to create the required ISO-MME files for sharing with Euro NCAP. Furthermore, the ISO18571 scores are calculated with the assistance of a Python script provided by Euro NCAP.

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Alexander Schif
DYNAmore GmbH, An Ansys Company

October 23, 2024 10:10 am

Break

October 23, 2024 10:30 am

Determination of MAT224 Fracture Surface Points for Material Subjected to Three-Dimensional State of stress

Aerospace Structure Impact & Dynamics II

LS-DYNA MAT224 is a tabulated material plasticity and fracture model. The plasticity part of the model can include strain rate, strain hardening and temperature effects. The fracture part uses a fracture surface that gives the value of the equivalent strain at fracture as a function of the state of stress (triaxiality and the Lode parameter). The fracture surface is made up of experimental data points. Each point corresponds to a specific combination of triaxiality and Lode parameter values. The value of the equivalent plastic strain at a point is obtained from an experiment in which the specimen is subjected to loads that generate the desired state of stress. Ideally, the specimen is loaded proportionally until it fractures and the value of the equivalent plastic strain at the fracture location is entered as a point in the fracture surface. When the model was first introduced the data points used for the construction of the fracture surface were obtained from relatively simple experiments like uniaxial tension tests, tension of notched flat and round specimens, pure shear, uniaxial compression, combined tension or compression with shear, and punch tests. The fracture data points from these experiments cover only a small portion of the fracture surface. In many applications fracture occurs when the material is loaded with combination of stresses that are not near the data points from the simple tests. One example is impact events associated with failure of jet engine rotating parts that impact containment and shielding systems where the penetration of debris involves plastic deformation and fracture under a three-dimensional state of stress. The present paper introduces new experiments that have been developed recently to support the MAT224 model by providing data points to the fracture surface at combinations of stresses (combinations of triaxiality and Lode parameter values) that are important in simulations of projectile impact and penetration. These stress states include biaxial equal and unequal in-plane tension and out-of-plane compression and plane strain compression. The new experiments consist of spherical and elliptical miniature punch tests of a thin specimen plate supported by a backup plate and compression of a notched ring. Digital Image Correlation (DIC) is used in all the tests to measure deformations. Numerical simulations of the tests are performed using an assumed plasticity model, and the model stress prediction is validated by matching the simulated force-displacement response and strain with the experiments.

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Amos Gilat
Ohio State University

October 23, 2024 10:30 am

Simulation of drug effects on whole heart contractility

Biomedical/Healthcare II

The human heart beats as a result of certain multiscale electro-mechanical mechanisms, ranging from subcellular to whole organ processes. Computational modelling and simulation (i.e. in-silico) studies have significantly assisted in advancing cardiac science over the last two decades. These studies permit a thorough understanding of patho-physiological mechanisms which usually involve smaller scales than those observed in a clinical setting. 

Electro-mechanical whole heart models usually consist of four different subcomponents: tissue electrical diffusion (I), tissue mechanical deformation (II), cellular electrophysiology (also called action potential models) (III), and cellular active contraction models (IV). Both I and II subcomponents act at the macroscale, and involve a set of bidirectionally coupled PDEs. III and IV act at the cellular level (or at the microscale), and involve two separate, i.e. not strongly/directly coupled, systems of ODEs. I and III are coupled via a reaction term, leading to a reaction-diffusion system of PDEs called either monodomain or bidomain equations. II and IV are usually coupled viaan active stress component.

As previously mentioned, whole heart cardiac simulations comprise of electrophyisiological and contractile cellular subcomponents which are not strongly coupled, and thus the effect of a strong electromechanical coupling at the cellular level on the whole heart has not been quantified yet. In this study, the action potential and active contraction coupling model of Margara et al. 2021 has been implemented in LSDYNA, and used in full heart electromechanical simulations. Simulations were then conducted using these models to quantify how does this strong electromechanical coupling affect key mechanical biomarkers: ejection fraction and end-systolic pressure. These were evaluated under healthy and drug exposed conditions. Drug effects were incorporated in the model by using IC50 and Hill coefficient data, as done in Passini et al. 2017, by means of simple poreblock models of drug action.

This study is, up to the authors’ knowledge, the first attempt at including a strongly coupled electromechanical cellular subcomponent in a whole heart simulation, and also at evaluating its behaviour under drug effects. The proposed simulation framework also offers the opportunity to extend whole heart simulations by including disease effects, which might be incorporated via other mechanisms, such as increased tissue mechanical stiffness and/or severely reduced tissue electrical diffusion.

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Francesc Levrero Florencio
Ansys

October 23, 2024 10:30 am

Simulation of hammer impact during driving process of offshore monopile foundation for wind energy structures

Drop/Impact Dynamics II

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Ahmed M. Abouelmaty

October 23, 2024 10:30 am

Evaluation of Viscoelastic Material Models in LS-DYNA based on Stress Relaxation Data

Material & Constitutive Modelling II

Viscoelastic behavior of a material is often used as a probe in the field of material science since it is sensitive to the material’s chemistry and microstructure. The behavior enables understanding of the quantity of energy absorbed by the material’s internal structure and the energy dissipated to the surroundings. The viscoelastic properties can be determined experimentally by tests such as stress relaxation, creep, or Dynamic Mechanical Analysis (DMA). Numerical modelling of rubber-like viscoelastic materials in terms of energy dissipation and energy storage is usually done using hyperelastic and viscoelastic constitutive models. Hyperelastic material model captures the material’s nonlinear elastic behavior with no time dependence. Viscoelastic model describes the material response as a function of time, frequency, and temperature, and contains an elastic and viscous part. This paper presents the dynamic characterization of rubber in terms of hyperelastic and viscoelastic constitutive models. The parameters of the constitutive models are determined from the uniaxial tensile and stress relaxation tests. These parameters are used for the numerical model of the rubber components and the accuracy of the characterization is presented by means of a numerical case study. Capabilities of different constitutive models available in LS-DYNA to predict viscoelastic behavior of rubbers viz., MAT76 (general viscoelastic), MAT77H (hyperelastic rubber) and MAT77O (Ogden rubber) are compared. Additionally, the recent developments under *MAT_ADD_INELASTICITY are discussed and recommendations are made for the usage of these models based on the material application.

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Vesna Savic
GM

October 23, 2024 10:30 am

Recent development in Ansys LS-DYNA's NVH solvers

NVH/Implicit 

LS-DYNA has been used by many automotive companies for many years, especially in the vehicle crashworthiness and occupant safety analysis areas. LS-DYNA also provides many useful features to help users to run NVH (Noise, Vibration and Harshness) analysis. During the past two years, numerous updates and enhancements have been made in the NVH solvers based on customers’ feedback and suggestions, including 1) A fast FRF analysis with reduced eigenvectors; 2) Frequency dependent adaptive remeshing for BEM acoustics; 3) Frequency interpolation for BEM acoustic solvers; 4) Fluid added mass computation and its application in modal and vibration analysis; 5) Coupling of acoustic spectral element method and piezoelectric material for ultrasonic sensors simulation; 6) Enhanced d3max output; and 7) New options and output in fatigue solvers. This paper aims at giving a brief introduction of these updates and enhancements to LS-DYNA users. Some examples are included in the paper for illustration purpose.

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Yun Huang
Ansys

October 23, 2024 10:30 am

Acceleration of Implicit LS-DYNA

Simulation Misc. I

Ansys has a four-decade history of using accelerators to speed up Computer-Aided Engineering (CAE).  The MAPDL Mechanical CAE code has been using Graphics Processing Units (GPUs) to accelerate implicit analyses since 2010. Following their lead, Ansys developers are now adding GPU acceleration to the linear and eigenvalue solvers in LS-DYNA. Meanwhile, the end of Dennard scaling, and arguably Moore's Law, has led to a proliferation of other accelerators, often designed to solve problems in Machine Learning and Artificial Intelligence. Ansys developers are also examining the feasibility of using some of these new devices as accelerators. In particular, we are looking to accelerate iterative linear solvers and NP-complete optimization problems. For memory bandwidth bound iterative solvers we are considering Xilinix Field Programmable Gate Arrays (FPGAs) and the Cerebras Wafer Scale Engine. For optimization, we are considering adiabatic quantum annealing with D-Wave and Pasqal, gate-model quantum computing with IBM, the digital annealers produced by Fujitsu and Toshiba, and LightSolver's optical system. Together with the vendors of the novel accelerators, we are doing this work in collaboration with UCLA, NETL, and BMW.

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Robert Lucas
Ansys

October 23, 2024 10:55 am

Application of the MAT 213 Composite Impact Model to NASA Problems of Interest

Aerospace Structure Impact & Dynamics II

A material model has been developed which incorporates several key capabilities which have been identified as lacking in currently available composite impact models.  The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength).  The material model has been implemented into LS-DYNA® as MAT 213.  The model can simulate the nonlinear deformation, damage and failure that takes place in a composite under dynamic loading conditions.  The deformation model utilizes an orthotropic plasticity formulation.  For the damage model, the nonlinear unloading response that is observed prior to the point where the peak stress is reached can be simulated, as well as the stress degradation response that occurs after the peak stress is reached.  A variety of failure models, including a generalized tabulated failure model which facilitates the utilization of general failure surfaces, have been implemented into MAT 213.  Recent studies at NASA have concentrated on using MAT 213 to analyze both the impact and crush response of a variety of laminated and textile architectures.  Several of these studies will be discussed in the presented paper.  For example, a woven carbon/Kevlar composite is currently being examined for use in an energy absorber system for rotorcraft structures.  MAT 213 analyses have been conducted to examine the ability of the model to accurately simulate the dynamic crush response of this material.  Studies are also being conducted to examine the ability of MAT 213 to simulate the ballistic impact response of representative laminated and woven thermoplastic and thermoset matrix composites.  NASA efforts are also concentrated on developing methods and processes for improving characterization methods and developing  “best practices” for using MAT 213, a summary of which will be discussed in the paper.

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Robert Goldberg
NASA Glenn Research Center

October 23, 2024 10:55 am

A New Eikonal Solver for Cardiac Electrophysiology in LS-DYNA

Biomedical/Healthcare II

Heart disease is among the leading causes of death in the Western world; hence, a deeper understanding of cardiac functioning will provide important insights for engineers and clinicians in treating cardiac pathologies. In this paper we will concentrate on the electrophysiology (EP) part of the physics, which describes the propagation of the cell transmembrane potential in the heart. In LS-DYNA, EP can be coupled with the mechanics and the fluid solvers for a Multiphysics simulation of the heart, but pure EP is also often used to investigate complex phenomena such as cardiac arrhythmias or fibrillations.  The gold standard model for EP is the “bi-domain” model, along with the slightly simplified “mono-domain”. These were introduced in LS-DYNA a few years ago. They give very accurate predictions, but the associated computational expenses are significant, which can be an issue for patient-specific predictions, for example, cardiac activation patterns for complex procedures such as cardiac resynchronization therapy (CRT). In this paper we introduce new computationally efficient eikonal and reaction-eikonal solvers. The eikonal method is very general and describes the propagation of a wavefront in a medium with given propagation velocities. The solution is the arrival time of the wave at each node, which corresponds to the activation time in the case of EP. This activation time can either be used to just trigger an action potential at each node independently, or a spatial diffusion term between nodes can also be added so that each node can influence its neighbors. The eikonal solver works on the 3D elements of the myocardium, but also on the beams composing the rest of the conduction system of the ventricles, i.e. the bundle of His, the left and right bundle branches, and the Purkinje network, which can all be coupled. Also, the eikonal solver can handle several waves by tracking more than one activation time per node. This allows for example to simulate reentry phenomena.   The eikonal solver will be presented and different examples will be shown.

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Pierre L'Eplattenier
Ansys

October 23, 2024 10:55 am

Advancing Solder Joint Modeling in PCBs: A Two-Scale Co-Simulation Approach for Shock & Vibration Analysis Using LS-DYNA

Drop/Impact Dynamics II

The integrity of solder joints in PCBs under dynamic loading conditions is critical for the reliability of electronic devices. Traditional modeling methods, such as representing solder joints with beam elements or solid elements in one-scale simulations, often face trade-offs between computational efficiency and accuracy. In this study, we introduce a two-scale co-simulation approach using LS-DYNA to address this challenge and provide both accuracy and efficiency in PCB analysis.  Conventionally, one-scale methods either sacrifice accuracy for computational speed by using beam elements or prioritize accuracy at the cost of computational efficiency through solid element modeling. However, our proposed two-scale approach strikes a balance between these two factors. By dividing the model into a global component representing the entire PCB assembly and a local component focusing solely on detailed solder joint modeling, computational resources can be optimized effectively.  A key advantage of the two-scale method lies in its two-way information exchange between the local and global models. Unlike traditional submodeling techniques, where information flow is typically one-way, our approach enables comprehensive communication between the global and local scales at each time step. This bidirectional exchange ensures that the effects of local solder joint behavior are accurately integrated into the global analysis, leading to improved accuracy compared to traditional one-scale methods.  To evaluate the effectiveness of the two-scale approach, we conducted a comparative analysis with one-scale simulations. Our results demonstrate that the two-scale method achieves superior accuracy, with an error rate of only 10% compared to the benchmark. Furthermore, the two-scale approach offers significant computational savings, reducing the running time by approximately 40% compared to one-scale methods. By accurately capturing the intricate dynamics of solder joints within the broader context of PCB assembly, our approach provides engineers with a reliable tool for optimizing the reliability and performance of electronic devices.  In summary, this study presents a novel two-scale co-simulation approach for shock and vibration analysis of PCBs, offering a balanced solution that combines accuracy and efficiency. By leveraging the advantages of both global and local modeling, our methodology represents a significant advancement in the field of PCB analysis.  Keywords: PCBs, Solder Joints, Shock and Vibration Analysis, Finite Element Analysis (FEA), Two-Scale Co-Simulation, Computational Efficiency.

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Henan Mao
ANSYS INC

October 23, 2024 10:55 am

Advancements in Eigenvalue Technology

NVH/Implicit

We will provide a overview of our work to improve the Lanczos, Fast Lanczos, and LOBPCG eigensolvers in LS-DYNA, especially focusing on the performance on large automotive models. We will describe our efforts of providing new technology for problems with additional physics such as rotational dynamics and the mixed-up formulation.

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Francois-Henry Rouet
Ansys

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Daniel Bielich
Ansys

October 23, 2024 10:55 am

A Physically based strength prediction model for glass

October 23, 2024 10:55 am

Efficient High-Performance Compute for Ansys LS-Dyna Leveraging NVIDIA Grace Platform

Simulation Misc. I

The NVIDIA Grace CPU, based on the ARM Neoverse V2 architecture, presents a significant advancement in High Performance Computing (HPC) through its focus on power efficiency and performance. The CPU is packaged as a "superchip," comprising of two 72 core Grace CPUs interconnected by a 900GB/s chip to chip link. This configuration is further supported by up to 960GB of LPDDR5X memory, which offers high bandwidth and low power consumption. The architectural improvements and memory integration enable the Grace CPU to achieve higher computational efficiency compared to alternative CPU designs.  Performance assessments using Ansys LS-Dyna simulations were conducted on both single-node and multi-node Grace Superchip systems. The results demonstrate that the Grace CPU platform provides comparable computational performance to existing HPC platforms, with the added benefit of improved power efficiency. These findings suggest that the Grace CPU is a new option for HPC applications like Ansys LS-Dyna, offering performance and energy efficiency.

October 23, 2024 11:20 am

Simulation-Aided Design of Compression Specimens for Accessing New States of Stress During Ductile Fracture

Aerospace Structure Impact and Dynamics II

In gas turbine engine blade-release or rotor-burst events, the impact and subsequent penetration of high-speed engine fragments with the engine case or aircraft structure are notoriously difficult to model and simulate.  A key ingredient in many state-of-the-art ductile fracture models is the failure locus, a three-dimensional surface plot of the equivalent plastic strain at fracture as a function of the state of stress, as quantified by the stress triaxiality and Lode parameter.  Generally, the failure locus is calibrated using standard mechanical tests.  However, these standard tests are only able to capture a limited window of stress states.  In this talk, to enable new states of stress at fracture, we present novel design permutations of recently proposed compression specimens with through holes and spherical recesses, as well as a combined compression-torsion specimen.  The geometry and arrangement of these through holes and spherical recesses provide a broad array of design permutations, while the combined loading allows for tailoring of different amounts of torsion and compression.  Preliminary simulations indicate compelling potential to add new ductile fracture data to the underpopulated positive (compressive) triaxiality region of the failure locus for aerospace metals.  The outcomes from this effort are expected to enhance the fidelity of predictive models used by the Federal Aviation Administration (FAA) Aircraft Catastrophic Failure Prevention Program and aircraft OEMs to simulate the impact physics of blade-off and rotor-burst events.

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Ethan White
University of Dayton

October 23, 2024 11:20 am

Pyheart-lib: A Python Library For LS-DYNA Multi-Physics Heart Simulations

Biomedical/Healthcare II

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Karim El Houari

October 23, 2024 11:20 am

Combining Physical Test with Structural Explicit FEA to Develop Package-Specific Failure Models for Electronic Components

Drop/Impact Dynamics II

Electronics use in vehicles has increased significantly over the past few decades and accounts for 40% of a new car's cost today.  Automotive electronic assemblies see high shock/vibration environments with mechanical shock experienced in a variety of scenarios such as a door slam, a vehicle crash or going over a pothole. The solder joints that connect the electronic components to their circuit boards are common failure locations in electronic assemblies, particularly in high shock/vibration environments and extreme power cycling conditions The failure behavior for a particular component's solder joints is heavily influenced by the component's package construction and materials.   Automotive qualification testing, which is required to ensure that component/system design meets verification and validation requirements with respect to performance and manufacturing, can be expensive and time consuming.  Using a finite element approach, component-level failure models can be used in conjunction with simulation to predict load-specific failure and virtually test designs to gain confidence ahead of physical qualification testing.  Ball grid array (BGA) packages, in mechanical shock and thermal cycling environments are common in automotive environments and were the focus of this workflow. The goal was to create both failure models and FEA strategies using a simplified test board that can then be used going forward whenever the electronic component is used in a real product design.  This presentation will outline how to create and validate simulation-based, component-specific failure models by correlating FEA to physical test. The component-level failure prediction approach is then extended to assess the reliability of these components when incorporated into larger assemblies. LS Dyna was used to solve FEA models in an Ansys workbench environment, using material properties derived from analysis and measurement of the components of interest.  Drop testing was conducted to tune and validate FEA model behavior at various stress levels and build confidence in the modeling approach.

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Mike Howard
Ansys, inc.

October 23, 2024 11:20 am

Considering the Local Anisotropy in the Simulation Process Chain for Short and Long Fiber Reinforced Thermoplastics

Material & Constitutive Modelling II

A huge number of short and long fiber reinforced thermoplastics play a decisive role in the automotive industry to ensure affordable lightweight design and availability in large quantities. The properties of these materials are especially highly influenced through the manufacturing process (typically injection molding for SFRT and LFRT). Over the last years, there is a strong industry interest to consider the manufacturing process induced local anisotropy inherent in these materials under a crash scenario. This paper is a collaborative work undertaken with our partner Dr. Ing. h. c. F. Porsche AG that deals with the material testing with IMPETUS® and the material modelling calibration process for a *MAT_4A_MICROMEC with VALIMAT® in LS-DYNA. Besides the validation of anisotropic material deformation behavior, the calibration of the failure behavior is also considered in extensive detail. To obtain such a high-quality material card a workflow is developed, starting with molding adequate plaques for test specimens to characterize the underlying deformation and failure behavior at the coupon level under different loading scenarios up to final validation on component level.

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Harish Pothukuchi
4a engineering GmbH

October 23, 2024 11:20 am

The new linear solver with nonlinear contacts

NVH/Implicit

October 23, 2024 11:20 am

Application of ISPG Method in Various Manufacturing Processes Simulation

Simulation Misc. I

Application of ISPG Method in Various Manufacturing Processes Simulation Li Zhang, Xiaofei Pan, Michael Su, Jingxiao Xu, C.T. Wu Incompressible Smooth Particle Galerkin (ISPG) theory was first proposed by the R&D team CMMG at LSTC back in 2017. It developed a new Incompressible Navier-Stokes solver for modeling of free-surface Newtonian and Non-Newtonian fluid flow with surface tension and adhesion force. The Lagrangian particle method was employed to discretize the ISPG part to approximate the Navier-Stokes equation, which is strongly coupling with surrounding rigid structures. ISPG method is fully implicit, and in its dynamic mode, it simulates in real time fluid behaviors in many applications. ISPG’s robust, in-core, and smart mesh adaptivity allows fluid flow in complex geometry, accurately capture and align the ISPG surfaces with the structure surfaces, while keeping the model size down. It also allows for ISPG part separation and fusion. The ISPG advanced material models allows for simulation of fluid behavior with various viscosity from water to near solid state. ISPG technology was first applied in solder reflow simulation back in 2019. Since then, with more features and improvement to the code, it found itself in many other interesting areas of applications. In this paper, we will focus on showcasing the various applications of the ISPG method spanning many industries, including, but not limited to, compression molding, adhesive flow; and in semiconductor manufacturing area, PCB solder paste printing and stencil removal, capillary flow (underfilling) of the PCB. The latter two are integral part of the Chip manufacturing process along with the solder reflow. We will also discuss the limitations of the method in its current state.

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Li Zhang
Ansys, Inc.

October 23, 2024 11:45 am

Development of Anisotropic Plasticity Model of Titanium-6Al-4V for *MAT_264 for Ballistic Impact Simulations

Aerospace Structure Impact and Dynamics II 

October 23, 2024 11:45 am

Simulation of Oldroyd-B viscoelastic liquid jets with LS-DYNA ICFD

Biomedical/Healthcare II

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Zlatko Solomenko
Ansys

October 23, 2024 11:45 am

Fast Study of Multiple Sizes Helmets and Design Shape Optimization using LS-DYNA, LS-OPT and DEP MeshWorks

Drop/Impact Dynamics II

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M. Seulin

October 23, 2024 11:45 am

Modelling of failure in aluminium high-pressure die castings

Material & Constitutive Modeling II

Aluminium high-pressure die castings (HDPC) are becoming more and more relevant parts in the automotive sector. This type of parts offers a high flexibility in terms of design which has been used to reduce significantly the number of parts in a car body and potentially save weight compared to traditionnal steel components. On the negative side, aluminium HPDC parts generally suffers from a low ductility (for non-heatred alloys) and considerable variations in failure strains. Designing such parts to sustain severe mechanical loadings is thus challenging since material variations can lead to catastrophic failure. To account for the stochastic character of aluminium HDPC materials, a large number of simulations, where the failure properties are varied in a random manner, should be carried out to capture the potential span of responses of the structure at hand. This procedure is however difficult to use in practice due to the potential large number of simulations to be carried out and analysed. In this work we will present an alternative approach where a single simulation is carried out and the probabilities of failure are computed a posteriori within a python environment. We will cover the aspects of calibration, its mathematical foundation and application of this method. Using this method we will discuss the stress-state dependency of the ductility of an aluminium HDPC alloy. Finally, we will demonstrate the applicability of this technique on a laboratory scale HDPC part.

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David Morin
Norwegian University of Science and Technology

October 23, 2024 11:45 am

Introduction of LS-DYNA MCOL solver coupling with Ansys Aqwa for the application in shipbuilding analysis

NVH/Implicit

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Zhe Cu

October 23, 2024 11:45 am

LS-DYNA Smoothed Particle Galerkin (SPG) method for ductile failure simulation: feature updates, development road map

Simulation Misc. I

CAE society faces a significant challenge in simulating dynamic deconstructive processing in 3D ductile or quasi-brittle solids such as metal, concrete, bone, wood, etc. Ansys researchers developed the LS-DYNA Smoothed Particle Galerkin (SPG) method for these types of application. Unlike other mesh-free methods, SPG uses direct nodal integration (DNI) without background mesh and a novel bond failure mechanism to predict the material failure behavior. The manufacturing processing such as drilling, grinding, and piercing usually involves large plastic deformation and complex sample/tool contact conditions. To address these technical demands, LS-DYNA developers released new features such as new contact algorithms which are compatible with particle/surface interactions, various damage models for different failure patterns. For the upcoming development road map, SPG developers focus on efficiency improvement with algorithm updates and heterogeneous computational platform: CPU/GPU hybrid calculations.

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Bo Ren
Ansys

October 23, 2024 12:10 pm

Lunch

October 23, 2024 01:15 pm

Experimental Calibration of Flow Rule Coefficients for LS-DYNA MAT_213

Aerospace Structure Impact and Dynamics III

Composite materials have become popular choices in aerospace engineering applications due to their low weight, high specific stiffness, high specific energy absorption, and more. As use of composite materials has proliferated, the need for accurate simulation under extreme loading conditions is of increasing importance. *MAT_213 is a tabulated plasticity and damage material model in LS-DYNA designed for such use cases. To account for the nonlinear material response, a plasticity algorithm is used which employs a non-associative flow rule. The coefficients of this non-associative flow rule require calibration for the user’s material of interest. This work outlines a methodology for calibrating these coefficients using data from coupon scale experiments. The model material used for development and demonstration of this methodology is a plain-woven fabric with T300 carbon fiber tows in the warp direction and Kevlar© 49 fiber tows in the weft direction. This fabric is encased in an Epon© 828/Epikure© 8552 thermoset epoxy matrix. Coupon-scale tensile testing performed at multiple fiber angles (carbon fibers oriented 0º, 22.5º, 45º, 67.5º, and 90º relative to loading axis) provides data for multiple calibration processes. The first is finding ratios between flow rule coefficients that result in the convergence of different coupon responses in the effective stress – effective plastic strain space. This is done in a similar albeit slightly more general fashion than previous works [1-3]. Additionally, transverse and axial strain responses for various fiber angles allow for the use of plastic Poisson’s ratio in global coordinates as an initial estimate for ratios of the flow rule coefficients. Flow rule coefficients found by this methodology are then used as input for LS-DYNA simulations of uniaxial tension, compression, and Iosipescu shear coupon tests at varying fiber angles. These results are quantitatively and qualitatively compared to macroscopic stress-strain curves and spatial distribution of experimentally measured strain maps within the tested configuration gauges. The conformity of the experimentally measured quantities with those derived from the simulations provide a means for assessing the quality of calibrated coefficients.

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Daniel Slaughter

October 23, 2024 01:15 pm

Adaptive FEM-DEM simulation of a soft missile impact on a reinforced concrete slab

Blast/Impact Dynamics

Introduction Modeling the behavior of reinforced concrete (RC) structures under the action of destructive loads, considering the non-linear material properties and the strain-rate effects, are prescribed according to the requirements of The International Atomic Energy Agency (IAEA) in the design of buildings and structures of Nuclear Power Plants (NPP) [1].  A soft impact of a body imitating an aircraft engine missile is considered according to experiments [2]. Such a study can determine the ability of RC structures to withstand the impact of an engine or other large aircraft fragment. The paper describes an approach to solving such a problem, especially for a large-thickness under-reinforced slab made of low-quality concrete. Such a combination of design parameters may prove challenging for FE modeling due to significant mesh distortions and the need to model material erosion.  Model and Methods Modeling a soft impact on an under-reinforced slab of low-strength concrete is a challenging computational problem for traditional mesh methods. The structure's stiffness is not correctly represented when a coarse FE mesh is used. If a fine FE mesh is used, the calculation is unstable due to large deformations of the elements. Requires element erosion techniques to be involved. However, this may cause the formation of internal voids in the structure and, therefore, will not allow it to comply with the laws of conservation of mass and momentum. In addition, there is a danger of using the criterion of element removal artificially introduced into the material model as a fitting parameter, which allows for achieving agreement with the experiment but does not give a physically correct solution.  The possibility of converting eroded mesh elements into discrete elements built into LS-DYNA is considered in the paper. The approach allows us to improve accuracy with the preservation laws and clarify the mechanics of structural failure. Thus, the solver can improve the demolished concrete behavior simulation and account for the fragments' interaction with the reinforcement cage, which is not available when converting elements to SPH particles [3].  Concrete material modeling is performed using the CSCM material model. In the standard version, this model is suitable for calculations of concrete with an unconfined axial strength of 34 – 45 MPa. However, the authors have developed and published a methodology that extends this range up to 20 – 60 MPa [4].  Summary The described technique provides one of the solutions to the problem of conservation of the laws of mass and momentum when erosion of elements is included in the issue of destructive loading of reinforced concrete structures. The calculations show good agreement with the experiment.  Literature [1] Novozhilov, Y., et al., "Aircraft NPP Impact Simulation Methodology" 16-th International LS-DYNA Conference, 2020, https://www.dynalook.com/conferences/16th-international-ls-dyna-conference/simulation-t9-2/t9-2-e-simulation-096.pdf/view [2] Sugano, T. et al., "Local damage to reinforced concrete structures caused by impact of aircraft engine missiles Part 2. Evaluation of test results," Nuclear Engineering and Design, Volume 140, Issue 3, 1993, Pages 407-423, ISSN 0029-5493, https://doi.org/10.1016/0029-5493(93)90121-O [3] Dmitriev, A., et al., "Simulation of Concrete Plate Perforation by Coupled Finite Element and Smooth Particle Hydrodynamics Methods," Construction of Unique Buildings and Structures, 92(9207) 2020, https://doi.org/10.18720/CUBS.92.7 [4] Novozhilov, Y., et al., "Precise Calibration of the Continuous Surface Cap Model for Concrete Simulation. Buildings," Buildings, Volume 12, Issue 4, https://doi.org/10.3390/buildings12050636

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Yury Novozhilov
CADFEM Germany GmbH

October 23, 2024 01:15 pm

Simulation of sheet metal forming using solid elements

Forming III

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Xinhai Zhu
Ansys

October 23, 2024 01:15 pm

Pre-processing IGA models with ANSA

IGA II

October 23, 2024 01:15 pm

Virtual Testing Protocols and LS-DYNA Pre and Post Processing Solutions in the Oasys LS-DYNA Environment

Pre and Post Processing

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Alasdair Parkes
Oasys LS-DYNA Environment

October 23, 2024 01:15 pm

LS-DYNA User-Defined Internal Ballistic Modeling

Simulation Misc. II

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Sirri Oguz
NASA

October 23, 2024 01:40 pm

Failure Analysis of Adhesive Joints for Composites

Aerospace Structure Impact and Dynamics III

October 23, 2024 01:40 pm

A new set of Eulerian Solver inside LS-DYNA

Blast / Impact Dynamics

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Hayley Easter
Ansys

October 23, 2024 01:40 pm

Trimline Development Application with Ansys Forming

Forming III

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Jeanne He

October 23, 2024 01:40 pm

CAD-integrated Untrimmed Body-fit Unstructured Spline LS-DYNA Preprocessing for Isogeometric Analysis and Digital Twins

IGA II

Isogeometric Analysis (IGA) has emerged as a next generation advancement in the field of Computer-Aided Engineering (CAE) and simulation thanks to its ability to utilize geometric representations native to Computer-Aided Design (CAD) models. LS-DYNA's proven capabilities for IGA has made it the premier solver for the technology. While the direct benefits for analysis are well documented, industrial adoption has been hampered by the difficulty in producing IGA-ready models from CAD data. Trimmed multi-patch IGA preprocessing approaches have seen advances at the industrial level but the desire for untrimmed body-fit unstructured splines has remained an unsolved approach in IGA preprocessing. In this paper, we discuss an IGA preprocessor for LS-DYNA that not only produces untrimmed body-fit unstructured splines but does so in a process that is integrated directly into a CAD application. This allows for a direct coupling between CAD and IGA alleviating the intersections between surfaces in the native CAD model consisting of approximations represented by curves rather than explicit surface-to-surface continuity, resulting in what is referred to as a “geometrically non-watertight” model. nVariate& technology creates a watertight spline CAD model in such a way that the intersections between surfaces are defined without gaps. We are able to retain all of the product and manufacturing information (PMI) associated with the original CAD model as well as provide a two-way link to the original design model. In addition, our unique watertight technology allows for model integration and a direct link to CAE from currently disparate domains such as Computer-Aided Inspection (CAI) and Computer-Aided Manufacturing (CAM). We show that not only is there a utility for IGA preprocessing in providing a CAD-integrated untrimmed body-fit unstructured spline technology for LS-DYNA but beyond preprocessing there are benefits for the synchronization of data across the digital thread in providing a representation for digital twins.

October 23, 2024 01:40 pm

Ensuring conformity and high level productivity between ANSA and LS-DYNA during model and load case development

Pre and Post Processing

October 23, 2024 01:40 pm

Spotweld Modeling Methodologies and Failure Characterization of Aluminum Resistance Spotwelds (RSW) using LS-DYNA

Simulation Misc. II

Robust joints in automotive body structure play vital role in structural performance during crash event. With increased use of Aluminum in vehicles, deep understanding of failure modeling of Aluminum Resistance Spotwelds is critical. This paper discusses failure card development of aluminum RSWs using LS-DYNA for certain 5xxx & 6xxx alloys used in structural applications. Detailed study and comparison of various material models was conducted, and appropriate model was chosen to effectively achieve project objective.    Several CAE sensitivity studies of failure parameters, weld modeling techniques, weld element orientation, parent material mesh size, tied contacts and heat affected zone were conducted. Findings were insightful and helped to select preferred modeling approach.      Various methods in failure model to improve axial loading prediction were evaluated and compared. Eventually, recommendations have been made to use appropriate keywords. Numerous simulations were run to study ‘post-failure damage’ modeling using *Mat_100_DA model. Results concluded to very interesting findings which indicated what care should be taken while using damage and using hex clusters.    For instance, it was found that the UNIAXIAL option might not fulfill its promises when the plates joined have different stiffness and a hex cluster is used. The hex cluster must be in a uniaxial stress state for the plastic strain to grow as expected. Two plates with different stiffness put certain elements of hex cluster in a mixed stress state. Local deformation in the plates generates shear stress components in hex cluster; if stiffnesses are different. The behavior during damage depends on how fast the hex cluster will reach (or not reach at all) a uniaxial tension stress state.   This paper examines the efficacy of different testing methods including flat coupon testing (Lap shear, Cross tension, and Coach peel) and KS-2 testing. The paper also elaborates types of tests conducted to develop failure cards and shows test to CAE correlation.    Overall, this paper delves into the failure modelling possibilities of a resistance spot welding for aluminum sheets, elucidating the impact of each variable involved in the modelling process. It also demonstrates comparison with physical test data and gives recommendations on preferred modeling approach.

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AKSHAY KULKARNI
Novelis

October 23, 2024 02:05 pm

Hourglass Control Recommendations for Simulating Reinforced Concrete under Low Velocity Impact

Blast/Impact Dynamics

The performance of reinforced concrete structural components under impact loading has received significant attention over the past decade using high fidelity numerical simulations to supplement the available experimental test data.  Several studies have evaluated the prediction of impact force and displacement time histories, as well as cracking and spalling, using a number of constitutive models in LS-DYNA.  Under-integrated hexahedral elements are typically used in these analyses with hourglass control introduced to suppress hourglass modes.  Prior studies have demonstrated the sensitivity of reinforced concrete impact analysis to hourglass coefficients, but the selection of hourglass coefficients has been limited to select comparisons with experimental time history measurements.  Furthermore, studies contrasting the performance of different constitutive models have routinely used a single hourglass coefficient for all models despite each constitutive model demonstrating unique sensitivity to the hourglass control.   To provide detailed insight into the effect of hourglass control type and coefficient on the simulated response of reinforced concrete to low velocity impacts, an extensive numerical campaign was conducted using experimental data from a series of five different reinforced concrete beam specimens subjected to drop hammer loading to validate the results.  Prevailing constitutive models for dynamic analysis of reinforced concrete, including Continuous Surface Cap, Winfrith, Karagozian and Case Concrete, RHT, and Concrete Damage Plasticity, are included in the investigation to examine the sensitivity of each constitutive model to the hourglass control parameters.  The study quantifies the influence that hourglass type and coefficient have on impact force, and displacement response, and relative hourglass energy.  Furthermore, the significant effect of hourglass control on fringes of maximum principal strain, which are typically used as an indicator for location and severity of cracking in reinforced concrete, is investigated.  Recommendations for establishing parameters for hourglass control in the simulation of reinforced concrete beams under low velocity impact are formulated for each constitutive model based on the results of the study.

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Amirmohammad Samadzad
University of North Carolina at Charlotte

October 23, 2024 02:05 pm

Trim curve development in forming simulation

Forming III

In blanking and trimming operations, selecting the right trimming curves is crucial to achieve the desired geometry in the final part. However, selecting the right trim lines can be challenging, especially parts that require multiple stamping operations. State-of-the-art Finite Element (FE) simulation tools assist designers in finding the optimal trim curves, avoiding costly physical experimentation.   One alternative is to manually adjust the trim lines in the FE model until the final part meets the dimensional requirements, which is a time-consuming approach and might not yield satisfactory results. To address this, ANSYS Forming introduces a dedicated functionality that automatically searches for the optimal trim curves.   In ANSYS Forming, the trim curve development iteratively adjusts the lines used in blanking and subsequent trimming operations. The simulation ends when the boundaries of the part are within a predefined tolerance of a target geometry.   In this presentation, we will introduce some recent enhancements related to this function and provide some usage guidelines. The latest updates to the trim curve development result in a faster convergence to the desired final geometry. To illustrate best practices, we provide relevant application examples from the automotive and semiconductor industry.

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Pablo Hernandez Becerro
Ansys

October 23, 2024 02:05 pm

Computation efficiency in IGA Solid by applying subcycling technology

IGA II

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Liping Li

October 23, 2024 02:05 pm

CAE Process Automation using ANSA and SPDRM for creating crash digital models

Pre and Post Processing

The advantages of process automation are widely known among CAE engineers: standardization of input data and work during the individual steps assuring a consistent result of a high level of quality (human error free),  drastic reduction of the CAE turnaround time by tackling complex tedious problems in an automatic repetitive way and  gives the capability to involve in the production engineers with less experience in the specialized processes.  This automation can take place on two levels. Either at the level of individual custom developed tools, which conduct complex repetitive processes, that are handled within ANSA with the automatic use of interrelated ANSA capabilities/functionality. Or in a more integrated wider environment (system), SPDRM, where the processes are more complex and extensive and where also the full automated management of the data between the various individual processes is taken over by the system.  Both cases will be explained by demonstrating corresponding examples. From the import of the CAD data and its preparation for the CAE processes, to the automated build of various subsystems of a digital crash model, to the set-up of the load case and finally to the export of the ready-to-submit files.

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ALEXANDROS KALOUDIS
BETA CAE Systems

October 23, 2024 02:05 pm

Use of LS-DYNA for Estimating Earthquake-induced Ground Settlements

Simulation Misc. II

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Ozgun Numanoglu

October 23, 2024 02:05 pm

Progressive Damage and Failure Analysis for Structural Continuous Fiber Composite

Aerospace Structure Impact and Dynamics II

October 23, 2024 02:30 pm

Validating wear simulations in heat exchanger plate stamping process through comparative analysis with experimental data for enhanced productivity and quality

Forming III

Mesh adaptivity refines the blank mesh as needed in stamping simulations. Users do not need to anticipate where a dense mesh will be required. Despite its universal use, it demands significant effort due to serialization and the need to carry a dense mesh through subsequent iterations. In-Core adaptivity and Mesh fusion assist the solver in conserving effort, thereby enhancing performance. This paper will demonstrate best practices for utilizing In-Core adaptivity and Mesh fusion in Ansys Forming through practical cases. In addition, for different model, we should find an optimum number of CPUs to run the job. Beyond this number, the scalability will not see any obvious improvements.

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Kang Shen
Ansys

October 23, 2024 02:30 pm

Continuum-based Particle Gas (CPG): A New Approach for Airbag Deployment Simulations

Simulation Misc. II

The evolution of automotive safety systems has witnessed a remarkable journey over the past few decades, with airbags emerging as pivotal components in mitigating the severity of injuries during vehicle collisions. Initially conceived as relatively simple passive restraint systems, airbags have undergone a profound complexification in their design and functionality, driven by the relentless pursuit of enhanced occupant protection and regulatory compliance. Today, modern vehicles incorporate a diverse array of airbags strategically positioned throughout the cabin to address various collision scenarios. From front and side airbags to curtain and knee airbags, this proliferation underscores the nuanced approach to occupant protection adopted by automotive manufacturers.  However, from a numerical analysis standpoint, this increased complexity has introduced new challenges. Modeling airbag deployment has been challenging from the outset due to the intricate dynamics of airbag inflation and the complex Fluid-Structure-Interaction (FSI) involving gas, airbag fabric, and internal components. While initial endeavors primarily aimed to accurately depict the interaction between occupants and fully inflated airbags, modern CAE tools must now also predict the entire deployment phase with exceptional precision, necessitating the incorporation of complex physics into the numerical methods. Developed two decades ago, the Corpuscular Particle Method (CPM), rooted in kinetic gas theory, quickly emerged as the preferred technique for sophisticated airbag modeling. This method adeptly handles intricate airbag designs and has demonstrated considerable utility. Nonetheless, the recent trend towards increasingly complex airbag designs, coupled with the growing need for high-fidelity resolution during initial deployment stages, has underscored certain shortcomings in effectively resolving local flow characteristics using this method. In our presentation, we introduce a novel method for simulating airbag deployment known as Continuum-based Particle Gas (CPG), which relies on continuum physics principles. Like CPM, CPG is a particle-based approach that eliminates the need for meshing the airbag & internal volume. However, CPG adopts continuum theory and resolves the compressible Navier-Stokes equation coupled with an ideal gas equation of state. Our emphasis will be on explaining the theoretical foundations of the CPG solver and showcasing numerical examples, supported by theoretical analysis or experimental findings where appropriate.

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Edouard Yreux
Ansys Inc

October 23, 2024 02:30 pm

Simulating Global Motion of the Brain in Response to Trauma: A Biomechanical Approach Florida Atlantic University - Wilkes Honors College

Aerospace Structure Impact and Dynamics III

October 23, 2024 02:30 pm

Overview of LS-TaSC and New Feature Highlights

Pre and Post Processing

October 23, 2024 02:55 pm

Break

October 23, 2024 03:15 pm

Using Analysis for Decision Making in Aerospace Applications

General Session

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Joseph Pellettiere
FAA

October 23, 2024 03:40 pm

Update on LS-DYNA Developments

General Session

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C.T. Wu
Ansys

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