Presentation of PAM-CRASH v2004

Part 2: Inputchecks
.

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General Situation
ƒ Problem for industrial CRASH/SAFE simulation:
ƒ Dataset is very large
ƒ Dataset is very complex
ƒ Dataset is assembled with components of
ƒ Suppliers
ƒ Colleagues
ƒ Old models (cut and paste)
ƒ Dangerous and wrong definitions very difficult to find
ƒ Solution:
ƒ Improve Solver data check
ƒ Solver has to be strict for data check

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V2004: Enhanced Data Checks

ƒ To improve model quality for more stable and

accurate results.
ƒ All switch able checks are activated by default.
ƒ Switch able checks can be turned off to produce
results without changing existing data sets.
ƒ But it is NOT recommended, to turn off the switch
able checks

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 Data Checks
+-------------------------------------------------------------+
! IMPORTANT - IMPORTANT - IMPORTANT - IMPORTANT - IMPORTANT !
+-------------------------------------------------------------+
! !
! THE FOLLOWING IMPROVEMENTS ON DATACHECK MAY STOP YOUR RUN: !
! !
! 1) AIRBAG SKIN AND CHAMBER ORIENTATION CHECK !
! 2) AIRBAG CLOSED VOLUME CHECK !
! 3) METRIC VERSUS INPUT MESH TOPOLOGY CHECK !
! 4) 4-NODE DEGENERATED HEXA ELEMENT !
! 5) INTERNAL ELEMENT ANGLE 0 or 180 DEGREE !
! 6) FRAME TYPE 1 AND 2 USED BY KJOINT, JOINT, THLOC !
! 7) 10-NODE TETRA WITH BAD ELEMENT SHAPE (NEGATIVE JACOBIAN)!
! 8) KEYWORD MATCH WITH 8 CHARACTERS !
! 9) NON COINCIDENT NODES FOR SLIPRING DEFINITION !
! 10) WRONG ANALYTICAL STRAIN RATE MODEL FOR MAT TYPE 25, 41 !
! 11) MATERIAL TYPE 301 WITH FAILURE AND ZERO DISTANCE !
! 12) NODE ID USED FOR MORE THEN ONE RBODY COG !
! !
! DATACHECKS 1, 2, 3, 4 AND 5 CAN BE SWITCHED OFF. !
+-------------------------------------------------------------+

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10 Node TET Element with bad element
shape
ƒ To avoid stability problems (neg. volume, timestep)
ƒ Two tests are implemented:
ƒ Position of the middle node
ƒ Calculation and check of the Jacobian at different
locations
ƒ Examples for bad position of the middle node:

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10 Node TET Element with bad element
shape
ƒ Examples for bad Jacobian

ƒ Both checks cannot switched off but can be

influenced by parameters.

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4 - Node Degenerated HEXA Element

ƒ Four node degenerated HEXA are too soft and not

efficient in terms of CPU time
ƒ Therefore the new four node TET should be used.
ƒ Example for degenerated HEXA

ƒ Test can be switched off:

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2D-Element Check:
Internal angle 0 or 180 degree
ƒ To avoid numerical problems (core dump, floating
invalid)
ƒ Contact algorithm (platform dependent): there is a
risc of 50% to get zero-area triangle in the contact-
algorithm
ƒ The error message given by the check:
*** ERROR *** QUAD 1 IS UNACCEPTABLE: TWO CONNECTED EDGES ARE
PARALLEL

ƒ Switched by
SHELLCHECK YES(/NO)

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Frame type 1 and 2 used by KJOINT,
JOINT and THLOC
ƒ To avoid confusion with frame types
ƒ Only Frame type 0 allowed for above entities (just to initialize)
ƒ During solution each entity treats and updates his own internal
frame
ƒ What happens if the same frame is used for more then one
KJOINT?
ƒ To improve DMP performance
ƒ Frame type 2 needs very expensive DMP communication even if
the frame is not used

ƒ Use the ESI-tool FIXFRAME to fix the model

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Wrong analytical strain rate model for
MAT 25, 41
ƒ To avoid confusion for users
ƒ Solver switch to support analytical law, but no INFO
or WARNING for users in previous version
ƒ Was implemented for V2001 solver (global
analytical strain rate switch). Never updated for 2G
solver

only ISTRAT=1 allowed

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Material type 301 with failure and zero
distance
ƒ Distance needed to predict tension/compression.
Failure will happen only for tensile load
ƒ Previous version uses segment normal if distance
is zero. But no info or warning for users.

ƒ The check is only active, when ITENS=0

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Node ID used for more then one rigid
body COG
ƒ This is not allowed and may lead to wrong results.
ƒ Never checked in previous 2G versions

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Keyword match with 8 characters

ƒ To be consistent with the manual

ƒ To make sure that a dataset passed the solver will
be processed by 3rd party pre processors/tools
(which strictly follow the manual) as well

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 Airbag Skin and Chamber Orientation
Check

ƒ Pressure and volume

calculation depends on
uniform airbag outer surface
orientation !
ƒ Element normals need to point
‚outwards‘
ƒ Pressure direction wrong, for
elements with reversed
orientation
ƒ Consequence: different
mechanical behaviour

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 Airbag Skin and Chamber Orientation
Check (contd.)
ƒ Possibilities to check
ƒ CrashSafeEditor
ƒ Mesh → Normals Orientation → Show
Normals are displayed in the graphical window
ƒ Safety → Airbag Definition → Check
Warning message is issued
ƒ Solver
ƒ Error message in output listing (see below)
BEGINNING OF AIRBAG CHECK

CHECK FOR AIRBAG ID. 1

*** ERROR *** AIRBAG ID. 1 CHAMBER NUMBER 1 : ORIENTATION OF SURFACE

NOT UNIQUE
LIST OF ELEMENTS WITH INCONSISTENT ORIENTATION:
161 162 163 164 165
166 167 168 169

END OF AIRBAG CHECK

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Airbag Skin and Chamber Orientation
Check (contd.)
ƒ Force solver to ignore
ƒ Optional keyword

AIRBAGCHECK NO

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 Airbag Closed Volume Check
Case 2: influence not
Case 1: obvious (volume not
considerable closed at ‚inflator‘
ƒ Consequence of non- influence location, ‚hole‘ fixed by
BOUNC)
closed volume
ƒ Volume calculation
wrong
ƒ Consequently pressure
calculation wrong
ƒ Influence on results
depends on location of
elements
ƒ Case 2: supporting
structure may be
loaded

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 Airbag Closed Volume Check (contd.)

ƒ Possibilities to check
ƒ Mesh generation tool
ƒ Look for free edges
ƒ CrashSafeEditor
ƒ Safety → Airbag Definition → Check
Warning message is issued
ƒ Solver
ƒ Error message in output listing (see below)
BEGINNING OF AIRBAG CHECK

CHECK FOR AIRBAG ID. 1

*** ERROR *** AIRBAG ID. 1 CHAMBER NUMBER 1 : VOLUME NOT CLOSED
HOLE IS COMPOSED BY THE FOLLOWING ELEMENTS:
131 134 135 136 161
162 225 228

END OF AIRBAG CHECK

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Airbag Closed Volume Check (contd.)

ƒ Force solver to ignore

ƒ Optional keyword

AIRBAGCHECK NO

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 Metric Topology Check

Approximate mesh
ƒ Background
ƒ Approximate and reference
mesh need to be topologicaly
identical, i.e. edge numbers
between both meshes must be
consistent
ƒ In case of disconnected Reference mesh
meshes, corresponding edges
need to have identical length
ƒ If these requirements are
not met, unphysical initial
stresses occur

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 Metric Topology Check (contd.)

ƒ Possibilities to check
ƒ Mesh generation tool
ƒ Solver
ƒ Error message in output listing (see below)

BEGINNING OF METRIC CHECK

PARAMETER VALUES :

EDGE TOLERANCE FOR DISCONNECTED ELEMENTS .. 0.5000E-01

*** ERROR *** ELEMENT ID: 14 MESH TOPOLOGY OF INPUT FILE AND METRIC FILE
DOES NOT FIT. CHECK CONNECTIVITIES

*** WARNING *** EDGE LENGTH IS DIFFERENT BETWEEN INPUT FILE AND METRIC FILE FOR
DISCONNECTED ELEMENTS: 2 AND 3

*** WARNING *** EDGE LENGTH IS DIFFERENT BETWEEN INPUT FILE AND METRIC FILE FOR
DISCONNECTED ELEMENTS: 12 AND 13

END OF METRIC CHECK

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Metric Topology Check (contd.)

ƒ Force solver to ignore

ƒ Optional keyword

METRICCHECK NO

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 Slipring Nodes Coincidence Check

ƒ Slipring node (= structure

attachment node) and attached
node, need to be at the same
location
ƒ Otherwise constraint algorithm
does not work exact

$ idsr nodfx fric tol fract

SLIPR / 1 103 0.2 0.01 0.1
NAME slipring
$
ELE 11 12
END
ELE 13 14
END

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KW Selection

ƒ The following data checks are improved:

ƒ KW selection ERROR because of non existing parts, nodes or
elements

ƒ Error message for elements with missing part definition

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