Finite Element Simulation of Crash Test and Crashworthiness with LS-Dyna, Abaqus and PAM-CRASH

Many real-world engineering situations involve severe loads applied over very brief time intervals. While testing is crucial to analyze these types of loading scenarios, it can be expensive and sometimes economically infeasible to conduct physical tests when the cost of each prototype is prohibitively high. Moreover, data from a single physical test can be insufficient and companies cannot afford to conduct several of them for more detailed information.
Crashworthiness focuses on occupant protection to reduce the number of fatal and serious injuries. This research is responsible for developing and upgrading test procedures for evaluating motor vehicle safety. Crashworthiness research encompasses new and improved vehicle design, safety countermeasures and equipment to enhance occupant safety.
Finite Element Analysis (FEA) has been the trend in virtual crash design over the last decade. The predictive capabilities of FEA allow engineers to fully understand a crash event in a virtual environment, thus limiting the number of physical tests that need to be executed and thus saving costs.
ESimLab engineers simulate the crash safety with innovative CAE and virtual prototyping available in the non-linear structural codes: LS-DYNA, PAM-CRASH, RADIOSS and ABAQUS. We offer advanced FEA modeling consultancy services. We are experienced with automotive crash safety and consumer crash test protocols such as FMVSS208 (frontal impact), FMVSS214 (side impact), IIHS and EuroNCAP. Our engineers have Tier1 backgrounds in FEM (Finite Element Method) and are fluent in the codes: LS-DYNA, PAM-CRASH, RADIOSS and ABAQUS.

CFD and FEA consultant at ESimLab

FEA and CFD Based Simulation

Finite Element Simulation of Crash Test and Crashworthiness with Ls-Dyna, Abaqus and PAM-CRASH
FEA Finite Element Simulation of Crash Test and Crashworthiness with Ls-Dyna, Abaqus and PAM-CRASH

Heavy Trucks Crash Test Simulation

Heavy Truck safety is focused on occupant safety and underride guards.  Heavy truck occupant safety examines the causes of fatality and injury for heavy truck occupants, while truck underride research identifies the characteristics of underride events and contributing factors.

  • Truck Underride
  • Truck Occupant Safety

Small Overlap / Oblique Crashes

Studies show that fatalities still happen with vehicles equipped with safety belts and airbags in both small overlap and oblique crashes. Small overlap crashes are crashes with all the damage outside the main longitudinal member. Oblique crashes engage one of the main longitudinal members and cause the occupant to move in an oblique manner. Therefore, the agency is trying to develop test procedure to reduce fatalities and injuries in these two crash modes.

School Bus Crashworthiness & Crash Test

The governments try to ensure children safety in School Bus. But for investigation of crash effect and unwanted occurrences on children and level of injury, Finite element Method must be used to record force that transfer to the body in School bus and studying the absorbing mechanism and its level

Side Impact FEA Finite Element Simulation of Crash Test and Crashworthiness with Ls-Dyna, Abaqus and PAM-CRASH
Dummies FEA Finite Element Simulation of Crash Test and Crashworthiness with Ls-Dyna, Abaqus and PAM-CRASH
Composite Crash Test Simulation FEA Ansys Abaqus Lsdyna Finite element

Occupant Restraint Systems

Occupant restraint systems are intended to control occupant motion within the vehicle during the crash. Occupant restraint system technologies (e.g. air bags, seat belts, seats, etc.) are continually advancing and are a major contributor to mitigating crash fatalities and injuries. However, a significant number of crash injuries still occur, and efforts are ongoing to further improve restraint effectiveness. Occupant restraint system development continues to evolve as new regulations and consumer demand drive more complex solutions:
  •  Advanced Air Bag Technology Research
  •  Air Bag Aggressivity Study
  •  Side Airbag Out-of-Position FEA Study

FEA of Frontal Crash Protection

Frontal crashes are a major source of injuries and fatalities in the field. we use FEA dummies to evaluate occupant protection in frontal impact crash test. These efforts study occupant response, possible implications for smaller occupants, and restraint effectiveness for a rear seat passenger:

  • Determination of Frontal Offset Test Conditions Based on FEA Crash Data
  • FEA Approaches to Occupant Response

FEA of Airbag Effectiveness in Crash Test

The deformation mechanism of vehicles was analyzed in full frontal, offset frontal and side impact scenarios. ESimLab use non-linear structural codes LS-DYNA, PAM-CRASH, RADIOSS and ABAQUS program to FEA of Airbag Effectiveness in Crash Test and its effectiveness studied in dummy in different position. The simulation results were compared with actual crash test data of the corresponding vehicles. Reliable Numerical Simulation reduce the number of crash tests required during the automobile design process.

Dummies for crash Test Simulation:

  • Frontal impact dummies
    • Hybrid II (50th percentile) rigid dummy for aeronautics applications
    • Express Hybrid III 50th, & 5th percentile dummies
    • Hybrid III 50th, 95th & 5th percentile dummies
  • Side impact dummies:
    • ES2 & ES2-re
    • FTSS SID-IIs SBL C & D
    • US SID
    • WorldSID 50%
    • WorldSID 5%
  • Rear impact dummy
    • BIORID IIg
  • Child dummies
    • Hybrid III 6 years
    • Hybrid III 10 years
    • P series 3, 6 and 10 years, 18 months
    • Q series 3 years
    • CRABI 12 months
  • Pedestrian impactors
    • Head (EEVC adults and Child, FMVSS 201)
    • Pedestrian Head forms EEVC
    • Lower leg EEVC impactor
    • Upper leg EEVC impactor
    • Standing HIII 50th rigid dummy
    • Standing HIII child 6 years rigid dummy
  • Human dummy model
    • Complete human model: Humos2
    • Human head, leg and foot models
  • Barriers :
    • Frontal barriers
    • ODB (ECE 94 frontal regulation) solid & shell models
    • PDB V8XT proposed by EEVC WG 15 for crash impact compatibility – shell & solid models
    • TRL full width (consumer information test NCAP) – shell & solid models
  • Side barriers
    • NHTSA FMVSS 214 – solid & shell models
    • Progress ECE 95– solid & shell models (Cellbond)
    • AEMDB V3.9 = new proposal to update regulation EEVC W13 – solid & shell models (Cellbond)
    • IIHS SUV Barrier – solid & shell models (Cellbond)
  • Rear barriers
    • RCAR IIHS low impact
    • US Rear impact barrier FMVSS 310
    • Rear impact ECE barrier
ESimlab help a Startup company to simulate new special Concrete based designed "New Jersey" barrier crash test behavior to investigate its fracture pattern.
Finite Element crash model with belted male dummy Medical and Biomedical Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab
Truck and Trailer Finite Element Simulation Crash Test Crashworthiness Ls-Dyna Abaqus PAM-CRASH
Crash Test FEA Simulation Abaqus Ansys Ls-dyna ESIMLAB

Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.

FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.

Esimlab’s engineering team use advanced methodology and procedure in programming and correct constitutive equation in solid, fluid and multiphysics environment based on our clients needs.

We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.

ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.

Real world Simulation: Combination of experience and advanced analysis tools

Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, manufacturing ( Casting, Forming  and Welding) and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies.
ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development, enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.

CAE Simulation: CFD, FEA, System Modeling, 1D-3D coupling

Integrated expertise covering every Equipment component analysis. From concept through to manufacture and product launch, and for new designs or Equipment modifications, we provide engineering simulation expertise across projects of all sizes. Simulation has become a key enabling factor in the development of highly competitive and advanced Equipment systems. CAE methods play a vital role in defining new Equipment concepts.

metal forming simulation: ansys abaqus simufact forming
Metal Forming Simulation
Automotive Engineering: Powertrain Component Development, NVH, Combustion and Thermal simulation, Abaqus, Ansys, Ls-dyna, Siemens Star-ccm EsimLab
Crash Test and Crashworthiness
Finite Element and CFD Based Simulation of Casting esi procast
Casting Simulation
Additive Manufacturing: FEA Based Design and Optimization with Abaqus, ANSYS and Nastran
Additive Manufacturing
MultiObjective Design and Optimization of Turbomachinery: Ansys Fluent, Numeca fine turbo, Siemens star-ccm+, simulia abaqus, Ls-dyna, Matlab
Design of Turbomachinery
CFD Heat Thermal simulation: Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab
CFD Heat Transfer
Fluid Structure Interaction FSI with Ansys Abaqus, Fluent Star-ccm Comsol
Fluid Structure Interaction FEA CFD FSI Abaqus Ansys Comsol LS-dyna Wind Turbine EsimLab
Fluid Strucure Interaction
Exhaust Acoustics and vibration: ESI va one, msc actran, abaqus, ansys, fluent, star-ccm , nastran
Acoustics & Vibration
Aerodynamic Simulation CFD Ansys Fluent Siemens Star-ccm+ Numeca xflow cradle
Aerodynamic Simulation
Ansys Fluent, Siemens Star-ccm+ Numeca fine , Avl Fire, Matlab
Combustion Simulation
Multiphase Flow Simulation Abaqus, Ansys, Fluent, Siemens Star-ccm+, Matlab
MultiPhase Flow Simulation
Fatigue Simulation Abaqus Ansys FE-Safe NCode Design Life FEA Finite Element ESimLab
Creep & Fatigue
Multibody dynamics MBD Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab, fortran , C++, Python
Multi-Body Dynamics (MBD)
composite impact simulation , Comsol Abaqus, Ansys, Fluent, Siemens Star-ccm+, Aerospace and defenceMatlab, Fortran, Python CFD FEA
Composite Design
welding FEA Simulation Simufact Welding ESI Sysweld Abaqus Ansys ESIMLAB
Welding Simulation
Optimization of Wind Turbine Composite Fracture Mechanic Damage Design Abaqus Ansys Finite Element CFD ESIMLAB
Multi-Objective Optimization
CFD and FEA based Fortran, C++, Matlab and Python Programming
Advanced Fortran, C++, Matlab & Python Programming