Recent and Ongoing

Developments in LS-DYNA
Dilip Bhalsod

14th Oasys LS-DYNA users meeting

January 26th 2017
LSTC Products

LS-OPT/LS-TaSC
LS-PrePost

LS-DYNA

Dummies & Barriers USA

No additional license cost

LS-DYNA Applications

Development costs are spread across many industries

Automotive Structural
Crash and safety Earthquake safety
NVH & Durability Concrete structures
FSI Homeland security

Aerospace Electronics
Bird strike Drop analysis
Containment Package analysis
Crash Thermal

Manufacturing Defense
Stamping Weapons design
Forging Blast and Penetration
Welding Underwater Shock Analysis

Consumer Products Biosciences

3
 LS-Run LS-PrePost
LS-PrePost
LS-Run

Windows
Keyword file Text editor
And Linux

LS-DYNA

Parametric
Command Line

Administrate
Launch Jobs and View
Jobs

Queing Jobs
 LSTC family of Dummies and barriers

214 ODB IIHS

shell/solid shell/hybrid shell/solid
AE-MDB ECER95
shell shell

RCAR Barrier RMDB

LSTC PDB Model Validation for Global NCAP
Progressive
Deformable Barrier
Released LSTC Dummy Models
Detailed Models FAST Models
HYBRID III 5th HYBRID III 5th
HYBRID III 50th HYBRID III 50th
HYBRID III 95th (scaled) HYBRID III 95th
SID IIs D SID IIs D
EuroSID 2 HYBRID III 5th Lower Body
EuroSID 2re HYBRID III 50th Lower Body
USSID HYBRID III 50th standing
HYBRID III 6-year-old Hybrid II shape for ECE-R29
Free Motion Headform Thor (by request)
Pedestrian Legforms
Hybrid III 50th Lower Body
 LS-DYNA - Current Capabilities

Includes coupled Multi-Physics, Multi-Scale , and Multi-Stage in one Scalable Code

Explicit/Implicit Discrete Element Methods

Heat Transfer Incompressible Fluids

ALE & Mesh Free
i.e., EFG, SPH, Airbag Particle CESE Compressible Fluids
User Interface
Elements, Materials, Loads
Electromagnetics
Acoustics, Frequency
Response, Modal
Methods Control Systems
LS-DYNA - One Code, One Model

Single Model for Multiple Disciplines

Manufacturing, Durability, NVH, Crash, FSI

Multi-physics and Multi-stage

Structure + Fluid + EM + Heat Transfer
Implicit + Explicit .

Multi-scale
Failure predictions, i.e., spot welds

Multi-formulations
linear + nonlinear + peridynamics +

The Neon crash model is courtesy of FHWA/NHTSA National Crash Analysis

Center
Strong Coupled Multi-Physics Solver

Thermal

ALES/SPH/CESE
/MeshFree EM

LS-DYNA
Implicit/Explicit

NVH/Acoustic ICFD

DEM

Computers that can handle multiphysics simulations are becoming affordable

Scalability is rapidly improving for solving multi-physics Problem
VOLVO XC90 GEN II Crash CAE model 2014

CrachFEM materials
Detailed HAZ welds
Rolling wheels
New powertrain models
New chassis models
Steering mechanics from
wheel to steering wheel
 VOLVO XC90 GEN II Crash CAE model 2014

Total number of elements: 17 200 000

Simulation time: 250ms
Number of CPUs: 480
Run time: 84h
Number of elements reduced from 19 400 000 (two
complete cars) due to memory issues.
Mortar Contact for Lagrangian/Classical FEM

Goal to make it simple and universal with minimal options

Additional CPU time for increased accuracy
Features and recent developments
Segment to Segment with Accurate Contact Stress Integration
Element Types Supported
Solids, Shells, Beams, Thick Shells, 2D solids (2D in SMP Implicit only)
Physical Geometry Contact
Flat edges on shells
Beams are cylinders with flat ends
Couples to rotations for beams to exert moments
Contact with sharp edges on solids and thick shells
Friction
Table, part and dynamic friction
Wear
Ongoing work
Implicit
High Order Element support
Explicit
Bucket sort frequency
SMP parallelism and Hybrid support
Pressure Tube

*DEFINE_PRESSURE_TUBE
Air filled silicone tube
embedded in bumper foam
Pressure sensors at tube ends
detects crash Bumper foam

Acoustic approximation of 1D Bumper shell

compressible Euler for pipes with Frame
varying cross section area
Tube defined by beam elements, Silicone tube
area changes due to contact
penetration
Implicit Development General Overview
Linear Solvers
Linear Algebra team constantly working on
efficiency related issues
Expand range of applications
Nonsymmetric solver available

Nonlinear Solver
New default in R9.0
Minimize total number of iterations and stiffness
reformations
BFGS
Robust line search
Cut-back strategies
Tolerances

Features
Think different
Accurate Modeling improves robustness and
convergence
Speed not as important as in explicit analysis

Output
Facilitate debugging
Binary d3iter (graphical) and ascii message
(text)
Implstat in LS-PrePost

Documentation
Appendix P and Theory Manual
Implicit Guide
Nonlinear implicit and mortar contact theory
 Mortar Contact
Several enhancements and improvements
Forming mortar contact now runs with deformable solid tools and honors
ADPENE
Support rotational degrees of freedom when contact with beam elements
Maximum allowable penetration takes master thickness into account
Account for sharp edges in solid elements
When solid elements are involved, default stiffness is increased by a factor of
10
The OPTT parameter on *PART_CONTACT for the contact thickness of beams
is now supported
Typical Implicit Applications

Characterized by
Contacts
High order elements
Rubbers
Prestress
Inteference
Initial stress/force

Courtesy of Kongsberg Automotive, Thule Sweden,

Volvo GTT and Dellner Couplers
Implicit Roof Crush

No speed up
Robust
Comparable to explicit
Satish Pathy and Thomas Borrvall,
Quasi-Static Simulations using Implicit LS-DYNA
History Management
Purpose, to facilitate and organize the post-
processing of history variables in the d3plot
database
*DEFINE_MATERIAL_HISTORIES
Allows to customize the history variable
output
Instability
Damage
Plastic strain rate
Spotweld closest to failure
Select a certain historyvariable in a
given part and material
A given history variable # will correspond
to the specific quantity listed in the
keyword
No contamination by combination of
materials
Effective plastic strain is effective plastic
strain
 Wear Processes
*CONTACT_ADD_WEAR
Archard and User wear laws
Post process wear in LS-PrePost
Modify geometry in LS-PrePost
based on wear, using
*INITIAL_CONTACT_WEAR
Tool
Blank holder
Blank
Iterations Initial
between geometry
LS-DYNA 1st
and LS- run
PrePost 2nd
run

Borrvall et al, 3rd

Simulation of Wear Processes in LS-DYNA run
Welding pre-processor in LS-PREPOST

Easy to set the weld order, properties and choose boundary conditions for
each process stage
Weld path and direction identified by beam elements
Color green indicates completed input
Version 4.3 in LS-PREPOST

Presentation by Mikael Schill: Recent Developments for Welding Simulations

in LS-DYNA and LS-PrePost
*MAT_ADD_GENERALIZED_DAMAGE (MAGD)

General damage model as add-on for other material models

Intention: non-isotropic damage as in aluminum extrusions, composites,
Up to 3 history variables as damage driving quantities (multiple GISSMO)
Very flexible due to input via *DEFINE_FUNCTIONs

*DEFINE_FUNCTION
101
Func101(d1,d2,d3)=1.0-d1

Keynote talk by P. Du Bois: A new versatile tool for simulation of failure in LS-DYNA
and the application to aluminum extrusions
*MAT_254 / *MAT_GENERALIZED_PHASECHANGE

Very general material implemented to capture micro-structure evolution in

welding and heat treatment
Up to 24 individual phases
For any of the possible phase transformation user can chose from a list of
generic phase change mechanisms:
Leblond,
JMAK,
Koistinen-Marburger,
Kirkaldy,
Oddy,

Parameters for transformation law are

directly given in tables
Additional features:
Transformation induced strains
Transformation induced plasticity (TRIP)
Temperature and strain rate dependent plasticity

Ongoing development
 Paperboard Modeling
Laminate
For shell or solid modeling
*MAT_PAPER (*MAT_274)
Hyp(er/o)elastic-plastic Paper on roll
orthotropic model
Out-of-plane elasticity non-linear in
compression
In-plane and out-of plane plasticity models
uncoupled
Creasing of paperboard
In-plane yield surface consists of 6 planes
(tension/compression in MD,CD,MD/CD)
Initial configuration
Out-of-plane yield surfaces in
compression and transverse shear
*MAT_COHESIVE_PAPER (*MAT_279) Fully compressed
For modeling delamination in conjunction with
*MAT_PAPER and shells
In-plane and out-of-plane models uncoupled
Normal compression nonlinearly elastic Relaxed
Normal tension and tangential traction given
by elastoplastic traction-separation law
Jesper Karlsson,
Two New Models for Paperboard Materials
*MAT_277 / *MAT_ADHESIVE_CURING_VISCOELASTIC

Curing of epoxy adhesives and implied changes of mechanical behavior

Curing kinetics computed with the Kamal model for degree of cure :
Visco-elastic material with Prony-series representation
State of cure dependence
G ( )

N -t N
G(t , ) G () Gi ()e i
G0 ()1 i 1.0 1 e-i t
i 1 i 1 G0 (1.0 )
WLF shift based on temperature
AT Tref
i (T ) aT (T ) i ,0 , ln aT
B T Tref
Chemical shrinkage as function of state of cure
Coefficient of thermal expansion as function of temperature and
degree of cure
*MAT_280 / *MAT_GLASS

New material model for fracture of glass

Developed as user material, now implemented as *MAT_280
Brittle smeared fixed crack model for shell elements (plane stress)
Failure criteria: Rankine, Mohr-Coulomb, Drucker-Prager,
Incorporates up to 2 cracks, simultaneous failure over thickness,
crack closure effect (no element deletion),
 Stacked elements

picture credit:
New keyword *PART_STACKED_ELEMENTS Wikipedia

Layered shell and/or solid element model for shell-like structures

Application examples: sandwich plate systems, composite laminates,
Definition of surface geometry and layup sequence
Automatic mesh generation by extrusion

t3

+ t2
=
t1

*NODE
*ELEMENT_SHELL *PART_STACKED_ELEMENTS
Fracture in Glass-PC-Glass Composite

Top View
Evolution of damage field (0~1)

Rear View
Windshield failure analysis by Peridynamics

Glass layers, Peridynamic Model, MAT_ELASTIC_PERI

vinyl layer, FEM Model,

MAT_PIECEWISE_LINEAR_PLASTICITY
Interface of Vinyl and glasses:
CONTACT_TIED_SURFACE_TO_SURFACE_OFFSET
Evolution of damage field (0~1)

top view rear view

*CONSTRAINED_SPR2

Multi-sheet connection for self-piercing rivets

Before: only 2 parts (master and slave)
Now: up to 4 additional extra parts
Question about interdependence of
connections and reproduction of
experimental results remains open
Ongoing development

Double hat profile

with extra layer
and 3-T SPR
connections
*CONTACT_AUTOMATIC_..._TIEBREAK_USER

User-defined interface for tiebreak contact

Alternative models to Dycoss and others can be implemented
Available for SMP and MPP

subroutine utb101(sig_n,sig_t,disp_n,disp_t,vel_n,vel_t,cn,ct,
. uparm,uhis,idcon,idsn,idms,areasn,areams,time,dt2,ncycle,crv,
. nnpcrv,temp,ifail,ioffset)
c
c User subroutine for tiebreak contact: OPTION=101
c
c Purpose: To define normal and tangential stresses and possible failure
c in a contact with tiebreak connection
c
c Variables:
c
c sig_n,sig_t = normal and tangential stress (output)
c disp_n,disp_t = normal and tangential displacement (input)
c vel_n,vel_t = normal and tangential relative velocity (input)
c cn,ct = normal and tangential stiffness (input)
c uparm = user defined tiebreak parameters (input)
c uhis = user defined tiebreak history variables (input/output)
c ...
Isogeometric Analysis:
Recent Enhancements
NURBS Meshes
Control Points
regular NURBS-patch Control Net

trimmed NURBS

trimming
curve
- standard in CAD

4 regular NURBS-patches

- reparametrization
- C0-lines at patch
boundaries
 *ELEMENT_SHELL_NURBS_PATCH

Unlimited number of trimming loops (NL).

Supported by LSPP.
trimming
curve
- standard in CAD

*ELEMENT_SHELL_NURBS_PATCH
1 2 3 4 5 6 7 8
Card 1 NPEID PID NPR PR NPS PS
Card 2 WFL FORM INT NISR NISS IMASS NL

Card X NEL
one trimming
loop Card Y E1 E2 E3 E4 E5 E6 E7 E8

NEL: number of edges for trimming loop

E i: Edge (Curve) ID defining this edge - use *DEFINE_CURVE with DATTYP=6
 *ELEMENT_SHELL_NURBS_PATCH

Trimmed
displacement
NURBS

Standard
displacement
Shell-Elements
 L-Shaped Thin Plate

Gravitational Simply
loading supported

Simply supported

Tied
contact
line
Free

Simply supported

Simply
supported
Edge to Surface Example P=2 3x3 Patches of Thin Shells

First bending mode.

Mesh.

Higher order mode

Perspective &
Side views
Large Deformation Constraint
Sensitivity to Master/Slave Choice

Nonuniform coarse mesh.

Master & slave sides reversed.
Response virtually identical in both cases.
Eigenvalues are somewhat different.
 Automatic Tying at Corners

Currently in development.
More testing for Reissner-Mindlin.
Issues regarding thin shells.
Tying Trimmed NURBS

Under development
*CONSTRAINED_NODE_TO_NURBS_PATCH

Tie any *NODE to a NURBS surface.

Possibility to apply force and displacement BCs.
May be helpful for spotweld-modeling.

Quadratic NURBS
(2x2 Elements)

Deformation
Quadratic NURBS
(10x10 Elements)
Deformation
Quadratic NURBS
(40x40 Elements)
Taylor Bar With NURBS Solid Elements

FEA: Node# 9933 FEA: Node# 171765 FEA: Node# 3333129

(reference)

The stress distribution are very

similar for all cases.
When node# increase, the
maximum stress is closer to the
reference one.

IGA: Node# 5517 IGA: Node# 9933

OpenMP for IGA: Enables Hybrid MPP

OpenMP is now available for IGA shells and solids

# CPU 1 4 # CPU 1 4
Clock time (minutes) 15 7 Clock time (minutes) 78 33
Combined FEA + IGA

Talk 6.2 Current Status of LS-DYNA Iso-geometric Analysis in Crash Simulation

Y. Chen, S-P. Lin, O. Faruque, J. Alanoly, M. El-Essawi, R. Baskaran
Combined FEA + IGA

Talk 6.2 Current Status of LS-DYNA Iso-geometric Analysis in Crash Simulation

Y. Chen, S-P. Lin, O. Faruque, J. Alanoly, M. El-Essawi, R. Baskaran
 Solid Formulation 24
New element formulation ELFORM = 24 on
*SECTION_SOLID
Accurate for large deformation, severe distortion
Selective reduced integration to alleviate volumetric locking
Supports *ELEMENT_SOLID_H8TOH27
Excellent behavior in bending with 1 element over plate
thickness!

normal force

time

Elform2 fine 27 node coarse 27 node fine

1 1.35 28
*AIRBAG_PARTICLE/IAIR=-1

At the beginning of the bag inflation, the bag pressure may drop below
ambient pressure due to jetting. When IAIR=-1, it will allow external vents
to draw in outside air
The feature has been extended for porosity leakage
Works also after CPM switch to UP airbag

External Vent
Porosity leakage

IAIR= IAIR=-1
1
 *DEFINE_CPM_VENT

Internal vent with uni-direction/cone angle

*DEFINE_CPM_VENT
VANG: The 7th field of the 2nd card Airbag Fabric (Part 1)
Only valid for internal vent

Venting direction

Internal vent (Part 2) Vang: cone angle

Xoff

Vent geometry center

Vent area
Particle release point

Vent area needs to be greater than 0

0< Vang < 270 degrees or Vang < 0 (uni-direction)
Xoff = 5.0e-4*characteristic length (This offset tries to
avoid vent to the wrong side.)
 *DEFINE_CPM_VENT

Internal vent with uni-direction/cone angle

10 deg

30 deg

disable/enable p2p contact to validate the cone angle

*DEFINE_CPM_VENT

Push out vent

New Method to capture Accurate Bag Kinematics

Chambers did not get filled in time

Current method IAIR=2

New method IAIR=4 Courtesy of Autoliv

Airbag deformed shapes at 42 ms

Improved airbag deployment
MPP Decomposition

*CONTROL_MPP_DECOMPOSITION_ARRANGE_PARTS
Part/Part Set ID, TYPE, NPROC, FRSTP

Part/Part Set ID

TYPE: 0 Part ID to be distributed to all processors

1 Part Set ID to be distributed to all processors

10 Part ID to be lumped into one processor
11 Part Set ID to be lumped into one processor

NPROC: Evenly distributed elements in above Part/Part Set to number of

NPROC processors

FRSTP: Starting MPP rank

These options only work with element distribution

*PARTICLE_BLAST
Ground Blast with Cylindrical Shaped Charge

Immersed in air particles

The residual deformation of the target viewed from inside the rig

Test Simulation
*PARTICLE_BLAST
Pressure fringe supported by LS-Prepost
 ICFD The DrivAer benchmark is part of the QA
Designed by TUM, Inst. For Aerodynamics. The objective is to perform automotive aerodynamics validation. It is a generic
reference model with a modern car geometry. There is wind tunnel experimental data for comparison. LS-DYNA provides
excellent agreement with the experimental data.

Configuration used in the study F_D_wM_wW. Fastback_Detailed underbody_with Mirrors_with Wheels

 ICFD DEM coupling

Mud and Snow Deposition. Potential applications include drug delivery, erosion of river bed and FSI using particle
bonding capabilities

DEM with capillary force coupled to a turbulent flow

ICFD Sloshing and slamming with FSI

Fluid Elastic Body Tuned Liquid Damping

Interaction Problem Problem

Waves
impacting on
structure
 EM - New battery module

New capabilities are being developed within the EM module in order to simulate short
circuits in batteries. The final objective is to be able to predict the combined structural,
electrical, electrochemical, and thermal (EET) responses of automotive batteries to crash-
induced crush and short circuit, overcharge, and thermal ramp, and validate it for
conditions relevant to automotive crash.

Lithium-Ion
cell

In collaboration with
J. Marcicki et al,
Ford Research and Innovation Center, Dearborn, MI
EM - New battery module

Battery charge effect

simulated by
introduction of a
Randles circuit model

r0 * i2 added to thermal
ITdU/dT added to thermal

Allow correct
Cu collector : Al collector : material mass,
EM+Thermal EM+Thermal heat capacity and
thermal conductivity
Separator: Anode : cathode :
Thermal Thermal Thermal
EM - Short-circuit simulation

R R
R rs

R
R rs

R R

Replace Randle circuit by

resistance
2 added to thermal
 Module Concept for User Defined Features (UDF)

Shared object approach and new

keyword *MODULE
To facilitate working with UDFs in
that
the content of the usermat
package is
reduced, replaced by *MODULE
To enhance flexibility when
incorporating features delivered
as shared objects by third parties
*MODULE_PATH: specify multiple
paths (directories)
*MODULE_LOAD: load dynamic
library (file name)
*MODULE_USE: define rules for
mapping user subroutines
to the model
 FRF with rotational dof

*FREQUENCY_DOMAIN_FRF
VARIABLE DESCRIPTION VARIABLE DESCRIPTION

DOF1 Applicable dof for excitation: DOF2 Applicable dof for response:
EQ.0: translational movement in vector VID1 EQ.0: direction given by vector VID2
EQ.1: x-translational or rotational dof EQ.1: x-translational dof
EQ.2: y-translational or rotational dof EQ.2: y-translational dof
EQ.3: z-translational or rotational dof EQ.3: z-translational dof
EQ.4: x-rotational dof
VAD1 Excitation input type: EQ.5: y-rotational dof
EQ.0: base velocity EQ.6: z-rotational dof
EQ.1: base acceleration EQ.7: x, y and z-translational dof
EQ.2: base displacement EQ.8: x, y and z-rotational dof
EQ.3: nodal force
EQ.4: pressure VAD2 Response output type:
EQ.5: enforced velocity by large mass method EQ.0: velocity
EQ.6: enforced acceleration by large mass method EQ.1: acceleration
EQ.7: enforced displacement by large mass method EQ.2: displacement
EQ.8: torque EQ.3: nodal force
EQ.9: base angular velocity
EQ.10: base angular acceleration
EQ.11: base angular displacement
 Structured ALE solver (S-ALE)

Newly implemented scheme for Arbitrary

Lagrangian Eulerian method
Same theory: advection (remapping), interface
reconstruction, FSI - coupling to Lagrange
structure
Different Implementation: new automated mesh
generation, much more compact solver,
time saving in searching and sorting, stable and
user-friendly
Structured ALE mesh automatically generated
by *ALE_STRUCTURED_MESH
SMP, MPP, MPP-Hybrid supported:
Redesigned algorithm enabled SMP parallelization
Enhancement on MPP efficiency
Documents, Tutorials, Examples on
http://ftp.lstc.com/anonymous/outgoing/hao/sale

Tank sloshing: S-ALE 32% faster than

ALE
Structured ALE solver (S-ALE)

Newly implemented scheme for Arbitrary Lagrangian Eulerian method

Applications: AWG/Orion problem (left) and oblique long rod penetration (right)
MPP single precision 12 cpu run
on 2.2G Xeon E5-4640 cluster

0.4 M elements

3 M elements

25
speedup
ALE S-ALE 20

total time 25,276 s 14,204 s

15
advection 11,140 s 5,350 s
10
FSI 5,746 s 3,983 s
5 # cores
memory 34M 23M
0
0 100 200 300 400