LS-DYNA AND LS-PrePost TUTORIAL

RECTANGULAR CRASHBOX
SUBJECTED TO AXIAL IMPACT
1. Introduction
LS-DYNA is one of the Finite Element Method (FEM) program for nonlinear dynamic analysis of the inelastic
structure. In general, FEM is a numerical tool which is use to solve engineering problem, for example
structural analysis. There are three steps in the analysis when using FEM program: Pre-Processing, Processing,
and Post-Processing, as shown in Figure 1. LS-DYNA is use for Processing step (calculate the problem using
FEM), while LS-PrePost is use for both Pre-Processing and Post-Processing steps (create the FEM model and
visualize the result).

Pre-Processing

LS-DYNA Processing LS-PrePost

Post-Processing
.
Figure 1 FEM program analysis diagram.
For automotive crash box analysis, the detail step of analysis diagram is shown in

Finite Element Geometry Definition

Pre-Processing Boundary Initial Contact Element Material Numerical Simulation

(LS-PrePost) Condition Condition Definition Property Property Control

Control Hourglass Database

Cards Definition Cards

Parts Application Setup

Processing
Numerical Calculation
(LS-DYNA)

Extract Data

Analysis
Post-Processing
(LS-PrePost)

Peak Mean Crushing Specific

Displacement Crushing Crushing Force Energy
Force Force Efficiency Absorption

Figure 2. In the Pre-Processing step, the geometry must defined in terms of a finite number of elements.
There are several ways to develop a geometry of the problem:
 Import the configuration from Computer Aided Design (CAD) software in the form of STEP or IGES
file and then generate the elements in LS-PrePost.
 Import the elements from mesh generator software, like Hypermesh from Hyperworks program.
 Create the geometry in the LS-PrePost and then generate the elements from the geometry.
 Generate the elements directly in the LS-PrePost program.
The first and second methods mostly used for complex geometry, while the third and fourth methods usually
used for simple geometry. After the geometry that consist of finite number of elements is generated, the next
step is determine the property and condition of the problem, such as element property, boundary condition,
initial condition, contact definition, material property, and simulation control.
 Finite Element Geometry Definition

Pre-Processing Boundary Initial Contact Element Material Numerical Simulation

(LS-PrePost) Condition Condition Definition Property Property Control

Control Hourglass Database

Cards Definition Cards

Parts Application Setup

Processing
Numerical Calculation
(LS-DYNA)

Extract Data

Analysis
Post-Processing
(LS-PrePost)

Peak Mean Crushing Specific

Displacement Crushing Crushing Force Energy
Force Force Efficiency Absorption

Figure 2 Crash box analysis diagram using LS-DYNA and LS-PrePost programs.
After finite element model of the problem generated, the next is Processing step, which is numerical
calculation using LS-DYNA software. The final step is Post-Processing that consist of extract the data from
the numerical calculation result and analyze the result data. For automotive crash box problem, the analysis is
to evaluate the impact characteristics of the crash box, which are consists of displacement, peak crushing force
(Pmax), mean crushing force (Pm), Crushing Force Efficiency (CFE), and Specific Energy Absorption (SEA).
2. Problem Description
A crash box with square cross-section is subjected to 75 kg of moving rigid body in 8 m s-1 axial impact. The
dimension of the crash box is shown in Figure 3.

Figure 3 Crash box dimension in mm.

The crash box is made from Mild Steel St37, which is a strain rate sensitive material, with material property
shown in Table 1 and the relation between effective plastic strain-true plastic stress data shown in Table 2.
Table 1 Material property of Mild Steel St37
property symbol value units
density ρ 7.33E-06 kg mm-3
yield strength σy 0.29 GPa
ultimate strength σu 0.46 GPa
strain-hardening exponent n 0.22
Cowper-Symmonds constant D 6.844 ms-1
Cowper-Symmonds constant p 4.12

Table 2 Effective plastic strain and true plastic stress data of Mild Steel St37
effective plastic strain, EPS true plastic stress (GPa), ES
0 0.2853
0.0226 0.3242
0.0516 0.3585
0.087 0.3862
0.1261 0.4084
0.1666 0.4279
0.2079 0.4459
0.25 0.4617
3. Numerical Simulation
3.1 Pre-Processing
3.1.1 Finite Element Geometry Definition
1. Click Curve
2. Click Polygon
3. In “Side Num” bar, insert value 4, push ENTER (It is important to push the ENTER button in the
keyboard to create a rectangular geometry. Otherwise, the geometry will be stay at default option,
which is a triangular geometry. For the next steps, when the “push ENTER” command appear, do
as it says to create an effect of your input/option)
4. In “Side Len” bar, insert value 50, push ENTER
5. Click Apply
6. Click Close
The rectangular geometry as the crash box cross-section will be generated as shown in Figure 4

Figure 4 Rectangular geometry as the crash box cross-section

1. Click Geometry Tools
2. Click Transform
3. In the “Transform Type” option, choose Translate
4. In the “Sel. geom” window bar, click Whole
a. In the “Source Entity” bar, the geometry selected (rectangular geometry, known as “Wire”) will
be appear
5. Click “Dir” bar and choose “Z”
b. In the bar below the “Dir” bar, the transformation vector, V(0.0, 0.0, 1.0) will be appear
6. In “Distance” bar, insert value 180, push ENTER
7. Click the option located in the right side of the “Distance” bar and choose “Z”
8. Activate the “Copy” box option
9. Click Apply
10. Click Close
The top end and the bottom end of the rectangular crash box are generated as shown in Figure 5.
Figure 5 Transformation result of the rectangular geometry for the top end and the bottom end of the
rectangular crash box.
It can be seen in the tree-view in the right side of the window (a) that the geometry for the top end and the
bottom end of the rectangular crash box are generated. The Wire 1/Loop 1 is the rectangular geometry in the
below, while the Wire 2/Loop 2 is the above as shown in Figure 6.

Figure 6 The tree-view geometry information

1. Click Element and Mesh
2. Click N-Line Mesher
3. In the “Type” option, choose 2 Lines Shell
4. In the “Mesh By:” option, choose Element Size
5. In the “Mesh Parameter” bar, insert value 5 in the S1 bar, push ENTER. Repeat this operation for S2,
S3, and S4 bar
6. In the “Part ID” bar, insert value 1
7. In the “Sel. geom” window bar, choose option Pick
8. Click one side of the rectangular geometry in the below (see Figure 7)
 9. Click one side of the rectangular geometry in the above, which on the same side of the selected side
of the rectangular geometry in the below.
10. Click Mesh It
11. Click Accept (see Figure 8)
12. Click Done (see Figure 9)

Figure 7 Procedure to generate elements using N-Line Mesher with 2 Lines Shell option

Figure 8 Elements generated using N-Line Mesher with 2 Lines Shell option
The elements are generated in the one side of the rectangular crash box as shown in Figure 9. These
elements are belong to the Part ID 1.
 Figure 9 Elements generated in the one side of the rectangular crash box
The next step is to generate elements for the other sides of the crash box, while maintaining the location of
the elements in the “Part ID 1”. In the LS-PrePost, after elements were generated, the program automatically
change the Part ID into the next ID, which is “Part ID 2”. In this particular case, the crash box has identical
element properties (element formulation, number of integration point, and thickness) and material property. It
is better to keep all the elements of the crash box in the same Part ID, which is “Part ID 1” in this particular
case.
13. Click the [.] button in the right side of the Part ID bar
14. In the “Link PART” window bar, choose Part 1 LSHELL1
15. Click Done
16. Click another side of the rectangular geometry in the below
(similar to step 8, see Figure 10)
17. Click another side of the rectangular geometry in the above
(similar to step 9, see Figure 10)
18. Click Mesh It
19. Click Accept (see Figure 11)
20. Click Done (see Figure 12)
Figure 10 Procedure to generate elements in another side of the rectangular geometry and maintain the
elements to be located in the same Part ID with the previous elements.

Figure 11 Elements generated in another side of the rectangular geometry and in the same Part ID with
the previous elements.
 Figure 12 Elements generated in the one side of the rectangular crash box
Repeat the step 13-20 for the rest of the rectangular side. Step 13-15 is important to maintain the same Part
ID for all the elements. It can be seen in Figure 13 in the tree-view that all of the elements are belong to the
Part ID 1, which is 1 LSHELL1

Figure 13 All elements are generated and located in the Part ID 1, 1 LSHELL1
Some nodes are located in the same coordinate location, and these nodes are not connected to each other. In
other words, each side of the rectangular crash box is not connected to its adjoin side. The next step is to delete
some nodes in the vertical edge of each side, so the elements in the corner is connected and become integrated
rectangular crash box.
1. Click Element Tools
2. Click Duplicate Nodes
3. In the “Tolerance” bar, set the value in the default value (in this case is 0.018)
4. Choose the Keep Smaller NID option
5. Click Show Dup Nodes (see Figure 14)
 Figure 14 Procedure to eliminate nodes in the similar coordinate location
It can be seen in Figure 15 that in the corner of the crash box some nodes are in the same coordinate location
and not connected (shown by yellow sign).
6. Click Merge Dup Nodes
This option will eliminate all nodes within tolerance value as it set in the step 3. Based on step 4, the
nodes which have higher ID will be merge into the nodes with lower ID.

Figure 15 Location of the nodes which have same coordinate location and not connected (shown by
yellow sign)
7. Activate “Show Free Edges”
This option will show the free edge of the geometry (shown by white sign, see Figure 16). The purpose
is to make sure that each side of the rectangular crash box is connected to its adjoin side. Based on this
result, it shown that the free edge is located in the top end and the bottom end of the rectangular crash
box (a), which is correct for this particular case. After the location of the free edge is correct, deactivate
the “Show Free Edges” option.
 Figure 16 Location of the free edges of the geometry
8. Click Accept
9. Click Done
The finite element model of the rectangular crash box is finished and the next step is to save this model.
Click File, choose Save, then choose Save Keyword (or push CTRL+S button).
1. Click Browse
2. Insert file name (in this case, insert SQ-50x50.k). To calculate the finite element model in LS-DYNA,
there are 2 file extensions allowed, “.k” and “.dyn”.
3. Click Save
4. In the “Output Version” option”, choose the suitable version of the LS-DYNA version and it depends
on the LS-DYNA software in the user PC/Laptop. In my case is V970 and the most update version is
V971_R8.
5. Click Save

Figure 17 Procedure to save the finite element model

The next step is to create the geometry for the impactor model as shown in Figure 18.
1. Click Element and Mesh
2. Click Shape Mesher
3. In the “Entity” option, choose Box Solid
4. In the X, Y, and Z bar, insert value as shown below
Pmin Pmax
X -50.00 50.00
Y -50.00 50.00
Z 180.01 190.01
5. Choose “Number” option. In the Vx, Vy, and Vz, bar, insert value 4, 4, 1, respectively.
6. In the “Target Name” bar, insert name “IMPACTOR”
7. In the “Target Part ID” bar, insert value 2
8. Click Create

Figure 18 Procedure to create impactor model

These input data will generate an illustration of the elements configuration (shown by yellow sign) based on
the input data as shown in Figure 19.
9. Click Accept
10. Click Done
 Figure 19 Illustration of the elements configuration based on input data
The impactor finite element model is generated as shown in Figure 20. It can be seen that the impactor model
has different Part ID compare to the rectangular crash box model. The Part ID for impactor model is 2, with
part name “IMPACTOR” (a), while the Part ID for rectangular crash box model is 1, with part name
LSHELL1.

Figure 20 Finite element model of impactor and rectangular crash box

3.1.2 Boundary Condition
1. Click Model and Part
2. Click Create Entity
3. Click Set Data
4. Click *SET_NODE
5. Choose “Cre” option
6. In the “SetID” bar, insert value 1
7. In the “Title(Optional)” bar, insert “CRASH-BOX_LOWER_NODES”
8. In the “Sel. Nodes” window bar, choose Area
9. Choose ByNode
10. Drag all nodes located in the bottom end of the rectangular crash box as shown in Figure 21

Figure 21 Procedure to select nodes for fix support boundary condition

11. The selected nodes will be shown by yellow sign as shown in Figure 22
12. Check the number of selected nodes. In this case is 40 nodes are selected
13. Click Apply

Figure 22 Procedure to create a set of nodes data for fix support boundary condition
14. The generated set of nodes data will be shown by black sign as shown in Figure 23
15. The generated set of nodes data also shown in the left side bar of the Create Entity window bar as “1-
CRASH-BOX_LOWER_NODES (nodenum=40) (sub:1)”
 Figure 23 Procedure to check the set of nodes data for fix support boundary condition
16. Choose “Cre” option
17. In the “SetID” bar, insert value 2
18. In the “Title(Optional)” bar, insert “IMPACTOR_NODES”
19. In the “Sel. Nodes” window bar, choose Pick
20. Choose ByPart
21. Click the impactor finite element model. When the nodes of impactor finite element model were
selected, yellow sign will appear as shown in Figure 24
22. Check the number of selected nodes. In this case is 50 nodes are selected
23. Click Apply

Figure 24 Procedure to select nodes for pure axial movement boundary condition
24. The generated set of nodes data will be shown by black sign as shown in Figure 25
25. The generated set of nodes data also shown in the left side bar of the Create Entity window bar as “2-
IMPACTOR_NODES (nodenum=50) (sub:1)”
Figure 25 Procedure to check the set of nodes data for pure axial movement boundary condition
26. Check the set of nodes data established for the boundary condition as shown in Figure 26
27. Choose “Show” option
28. Click None to eliminate the sign of the selected set of nodes data

Figure 26 Procedure to check the set of nodes data established for boundary condition
29. Click Boundary
30. Click Spc
31. Choose “Cre”
32. Choose ”Set”
33. In the “Sym plane” bar, choose All Fix[111111] option and activate all box option for X, Y, Z, RX,
RY, and RZ.
34. Click the NSID link
35. In the “Link SET_NODE” window bar, choose CRASH-BOX_LOWER_NODES
36. Click Done
37. Click Apply
38. The established boundary condition will be shown in the left side bar of the Create Entity window
bar as “NSet 1 (111111) (sub:1)” as shown in Figure 27

Figure 27 Procedure to establish fix support boundary condition

39. Choose “Cre”
40. Choose ”Set”
41. In the “Sym plane” bar, choose All Fix[111111] option and ONLY deactivate box option for Z
42. Click the NSID link
43. In the “Link SET_NODE” window bar, choose IMPACTOR_NODES
44. Click Done
45. Click Apply
46. The established boundary condition will be shown in the left side bar of the Create Entity window
bar as “NSet 2 (110111) (sub:1)” as shown in Figure 28

Figure 28 Procedure to establish pure axial movement boundary condition

3.1.3 Contact Definition
1. Click Model and Part
2. Click Keyword Manager
3. Choose “All”
4. Click CONTACT
5. Click AUTOMATIC_NODES_TO_SURFACE
6. Click Edit
7. Click Add
8. In the “CID” bar, insert value 1
9. In the “TITLE” bar, insert “IMPACTOR_TO_CRASHBOX”
10. In the “MSTYP” bar, choose option 3 (EQ.3: part ID)
11. In the “SSTYP” bar, choose option 3 (EQ.3: part ID)
12. In the “MSID” bar, click [.] button, and choose 2 IMPACTOR in the “Link PART” window bar
13. In the “SSID” bar, click [.] button, and choose 1 LSHELL1 in the “Link PART” window bar
14. In the “FS” bar, insert value 0.4
15. In the “FD” bar, insert value 0.3
16. Click Accept
17. In the right side of the “Keyword Input Form” window bar, check the contact established
18. Click Done

Figure 29 Procedure to established contact between impactor and rectangular crash box
19. Double click AUTOMATIC_SINGLE_SURFACE
20. Click Add
21. In the “CID” bar, insert value 2
22. In the “TITLE” bar, insert “CRASHBOX”
23. In the “SSTYP” bar, choose option 3 (EQ.3: part ID)
24. In the “SSID” bar, click [.] button, and choose 1 LSHELL1 in the “Link PART” window bar
25. In the “FS” bar, insert value 0.4
26. In the “FD” bar, insert value 0.3
27. Click Accept
28. In the right side of the “Keyword Input Form” window bar, check the contact established
29. Click Done
 Figure 30 Procedure to established contact within the rectangular crash box to avoid self penetration
3.1.4 Initial Condition
1. Click INITIAL, then Double click VELOCITY
2. Check the “Keyword Input Form” window bar is for INITIAL_VELOCITY
3. In the “NSID” bar, click [.] button
4. In the “Link SET_NODE” window bar, choose 2 IMPACTOR_NODES
5. Click Done
6. In the “VZ” bar, insert value -8
7. Click Accept
8. Click Done

Figure 31 Procedure to establish initial velocity

3.1.5 Element Property
1. Click SECTION
2. Double click SHELL
3. Click Add
4. In the “SECID” bar, insert value 1
5. In the “TITLE” bar, insert SHELL_CRASH-BOX
6. In the “ELFORM” bar, choose 2 (EQ.2: Belytschko-Tsay (default))
7. In the “NIP” bar, insert value 2
8. In the “T1” bar, insert value 1. The others bar will be filled automatically.
9. Click Accept
10. In the right side of the “Keyword Input Form” window bar, check the element property established
11. Click Done

Figure 32 Procedure to define element property for crashbox finite element model
12. Double click SOLID
13. Click Add
14. In the “SECID” bar, insert value 2
15. In the “TITLE” bar, insert SOLID_IMPACTOR
16. In the “ELFORM” bar, choose 1 (EQ.1: constant stress solid element (default))
17. Click Accept
18. In the right side of the “Keyword Input Form” window bar, check the element property established
19. Click Done
 Figure 33 Procedure to define element property for impactor finite element model
3.1.6 Material Property
1. Click MAT, double click 024-PIECEWISE_LINEAR_PLASTICITY
2. Check the “Keyword Input Form” window bar is for
MAT_PIECEWISE_LINEAR_PLASTICITY_(TITLE) (024)
3. Click Add
4. In the “MID” bar, insert value 1
5. In the “TITLE” bar, insert St37_CRASHBOX
6. Insert the material property input bar based on data below
RO E PR SIGY
7.330e-006 222 0.3 0.2853
7. Insert the Cowper-Symmonds constant input based on data below
C P
6.844 4.12
8. Insert the Stress-Strain data point input based on data below
EPS1 EPS2 EPS3 EPS4 EPS5 EPS6 EPS7 EPS8
0.0000 0.0226 0.0516 0.0870 0.1261 0.1666 0.2079 0.2500
ES1 ES2 ES3 ES4 ES5 ES6 ES7 ES8
0.2853 0.3242 0.3585 0.3862 0.4084 0.4279 0.4459 0.4617
9. Click Accept
10. In the right side of the “Keyword Input Form” window bar, check the material property established
11. Click Done
 Figure 34 Procedure to define material property for rectangular crashbox
12. Double click 020-RIGID
13. Click Add
14. In the “MID” bar, insert value 2
15. In the “TITLE” bar, insert RIGID_IMPACTOR
16. Insert the material property input bar based on data below
RO E PR
7.500e-004 193 0.3
17. Click Accept
18. In the right side of the “Keyword Input Form” window bar, check the material property established
19. Click Done

Figure 35 Procedure to define material property for impactor

3.1.7 Numerical Simulation Control
3.1.7.1 Control Cards
1. Click CONTROL, double click TERMINATION
2. Check the “Keyword Input Form” window bar is for CONTROL_TERMINATION
3. In the “ENDTIM” bar, insert value 40
4. Click Accept, then click Done

Figure 36 Procedure to define termination time

5. Double click TIMESTEP
6. Click Accept, then click Done

Figure 37 Procedure to define timestep

3.1.7.2 Database Cards
7. Click DATABASE
8. Double click ASCII_option
9. Activate GLSTAT
10. In the “DT” bar, insert value 0.05
11. Activate RBDOUT
12. In the “DT” bar, insert value 0.05
13. Activate RCFORCE
14. In the “DT” bar, insert value 0.05
15. Click Accept
16. Click Done

Figure 38 Procedure to set energy output data

Figure 39 Procedure to set force and displacement output data

17. Double click BINARY_D3PLOT
18. In the “DT” bar, insert value 0.05
19. Click Accept, then click Done
 Figure 40 Procedure to set graphics output data
3.1.8 Hourglass Definition
1. Click HOURGLASS
2. Double click HOURGLASS
3. In the “TITLE” bar, insert CRASHBOX
4. In the “IHQ” bar, choose option 5 (EQ.5:Flanagan-Belytschko stiffness form with exact volume
integration for solid elements)
5. In the “QM” bar, insert value 0.05
6. Click Accept, then click Done

Figure 41 Procedure to define hourglass

3.1.9 Parts Application Setup
1. Click PART
2. Double click PART
3. In the right side of the “Keyword Input Form” window bar, choose 1 LSHELL1 part
 4. In the “TITLE” bar, insert CRASHBOX
5. In the “SECID” bar, click [.] button, choose 1 SHELL_CRASHBOX
6. In the “MID” bar, click [.] button, choose 1 St37_CRASHBOX
7. In the “HGID” bar, click [.] button, choose 1 CRASHBOX
8. Click Accept, then click Done

Figure 42 Procedure to setup crashbox part

9. In the right side of the “Keyword Input Form” window bar, choose 2 IMPACTOR part
10. In the “SECID” bar, click [.] button, choose 2 SOLID_IMPACTOR
11. In the “MID” bar, click [.] button, choose 2 RIGID_IMPACTOR
12. Click Accept
13. Click Done

Figure 43 Procedure to setup impactor part

Check the finite element model setup. The setup must similar with the setup in the Figure 44
 Figure 44 Finite element model setup for axial crushing simulation
3.2 Processing
Click LS-DYNA Manager as shown in Figure 45.

Figure 45 Open LS-DYNA Manager

1. Click Start LS-DYNA Analysis
2. Click Browse in the “Input File” bar
3. Choose SQ_50x50.k file
4. Click Browse in the “Output File” bar, choose the location of the output file
5. In the “NCPU” bar, choose the suitable CPU (depends on the user PC/Laptop)
6. Click RUN
 Figure 46 Preparation for the calculation
The program start to calculate the finite element model and the interface is shown in Figure 47. In the
rectangular sign will be shown the prediction of the calculation time.

Figure 47 The LS-DYNA interface of started calculation process

When the calculation process is done, there will be notification that say NORMAL TERMINATION as shown
in Figure 48. If there is a problem with the finite element model, the notification will say ERROR
TERMINATION.
 Figure 48 The LS-DYNA interface of finished calculation process
3.3 Post-Processing

Figure 49
Figure 50

Figure 51
3.3.1 Extract Data

Figure 52

3.3.2 Analysis
3.3.2.1 Displacement
3.3.2.2 Peak Crushing Force
3.3.2.3 Mean Crushing Force
3.3.2.4 Crushing Force Efficiency
3.3.2.5 Specific Energy Absorption