Step-by-Step Procedure for Front Impact Setup

1. Dummy positioning.
2. Creating dummy’s keyword file.
3. Belt routing.
4. Seat back and cushion foam morphing.
5. Front impact setup.
6. Preparing front impact seat model from a 207/210 setup.
7. Creating interface file.
8. Final model checks.

1. Dummy Positioning
Inputs: Dummy percentile, H-point, Torso angle, Heel point (or front seat plane
data), floor, seat structure and virgin foam (generally from 207-210 model).
1.1. Open LS-Prepost v4.2 and press F11 to switch from pull-down to panel mode
(panel mode is similar to v2.4 interface). Import the seat structure with virgin
foam, front seat planes (if provided) and floor model and then import specified
Hybrid III dummy using ‘Import Offset’ option. Ignore warnings if any.
1.2. Position the dummy using ‘H-Point operations  Translate’ as per the specified
H-point co-ordinates. Oftentimes, it is also required to rotate the dummy by 180
degree about z-axis using ‘H-Point operations  Rotate’ to face the dummy
forward. Adjust the dummy torso angle by rotating it about y-axis using ‘H-
Point operations  Rotate’ function again. If a heel point is provided by the
client, create a node from ‘Page-2  ElEdit  Node  Create’ panel. Using
this node as a reference, and using a series of ‘Limb operations’ visually
position the heel at the reference node. If heel point is not specified, position the
feet/leg such that there is no penetration with front edge of cushion foam and
front seat plane data. Always align the feet flat on the floor and if the floor is
uneven, ensure that the feet do not have any penetration with the floor. Align
the hands below the laps, because if they are above the laps then it might lead to
an early rebound of the dummy as the hands will touch the front seat planes in
front impact simulation. Make a thorough note of all the dummy operations
performed in this step.
1.3. Using ‘Page-1  SPlane  BaseNd  NormY  Cut’ operation, make cross
section planes at the center femur line and at the center of the dummy (Switch
on ‘Mesh’ outlining to visualize nodes to pick the SPlane base node). Check for
any penetration/gap of the dummy with the seat structure and foam using
section views and also the global 3D view. Measure the depth of the
penetration/gap using ‘Blank’ and ‘Measur’ (Page-1) options. Check the cross
sections for areas where the B-surface of the foam is in close proximity to the
dummy as this will create tetra collapse problem when the foam is morphed
(explained in Section-4 below).
1.4. If any issues are observed during Section-1.3 checks, move the dummy upward
or forward as needed. Limb operations may also be performed to clear the
issues (Need to quantify). Note down all these dummy operations thoroughly.
Create a PowerPoint presentation to obtain approval from client for these
updates/deviations.
1.5. Open a new LS-prepost session and import specified Hybrid III dummy file.
Position dummy using the operations recorded in step 1.2 (and 1.4 if any).
 1.6. Export the file as ‘ProjectName-DummyPercentile-Position(LH or RH or Cntr)-
wOriginalTree.k’ file.

2. Creating Dummy’s Keyword file

Inputs: ‘ProjectName-DummyPercentile-Position(LH or RH or Cntr)-wOriginalTree.k’.

2.1 Use “Transform_kg-mm-ms-to-ton-mm-sec-idoffset.k” file to change the units as

per the project and offset entity numbers of the dummy model according to
the table below.

Table 1
Dummy type Left Center Right
Hybrid III 5% 14000000 15000000 19000000
Hybrid III 50% 16000000 18000000 17000000
Hybrid III 95% 12000000 11000000 13000000

Table 1: For example the transform file for a 95% left dummy should look like:

2.2 Notice the dummy file saved in the step 1.10 is referred in the 6th line of the
“Transform_kg-mm-ms-to-ton-mm-sec-idoffset.k” file.
2.3 Run the “Transform_kg-mm-ms-to-ton-mm-sec-idoffset.k” file using LS-Dyna.
Edit the dyna.inc file and delete all control cards. In the file delete all control
cards (*CONTROL and *DATABASE. *DATABASE card just before
HISTORY NODE). Search for “*MAT_LINEAR“, delete the line containing
zeroes. After making the required changes, rename the file and also change
the file extension from .inc to .k. Please refer below picture for better
understanding. Highlighted yellow lines are to be deleted.
 2.4 The edited .k file should contain the dummy and be included in the master seat
model.

3. Belt routing:
Inputs: Anchor, D-ring and buckle coordinates (from the customer).
3.1.
2.5 Import the seat model into LS-Prepost v4.2 and then import the dummy saved
in step 2.4.
3.2. Belt routing is done using BeltFit option in Page 5 of LS-Prepost v4.2. The
picture below explains the use of Beltfit for creating belt elements.

3.3. After creating the belt elements save the file as belt.k file and import this file
in Hypermesh.
3.4. Delete dummy related entities. Write belt.k file with only belt elements.
3.5. If you are doing the belt routing for an existing seat model which had the belt
routing done previously, then create the 3 nodes in LS-PrePost as per the
existing co-ordinates and connect the belt.
4. Seat back and cushion foam morphing:
Inputs: Virgin foam and positioned dummy models.
The seat morphing can be done in a couple of ways as follows:-
4.1. Import the virgin foam and the dummy models into Hypermesh, check for
penetrations between the foam and the dummy.
4.2. Delete all foam elements.
4.3. Using Hypermorph function (tools panel) remove the dummy to fabric
penetration. Maintain a gap of 2mm between the foam ‘A’ surface and the
dummy.
4.4. Make a separate key file containing just the morphed fabric.
4.5. The dummy foam can also be morphed by moving along a vector and the
deformed cushion seat shape can be obtained and create the 3D seat foam.
4.6. The dummy foam can also be morphed by lifting the dummy in the ‘Z’ direction
and giving it a displacement downwards and similarly in “X” direction. The
deformed cushion seat shape can be extracted to create the 3D seat foam.

5. Front impact setup:

Inputs: Seat model, morphed foam, belt and dummy.
5.1.
1.1. Import the seat model with seat floor and front plane (if available) and belt.k
created above in Hypermesh in this sequence.
5.2.
1.2. Import the morphed foam file, equivalence the appropriate rigid elements to
cushion seat fabric elements. Check and confirm no free 1D are in display.
Move morphed cushion seat fabric elements to the respective component.
5.3. Repeat above steps for the remaining seat fabric components.
5.4. Check if the 2D belt elements are penetrating the foam. There should not be
any belt to foam penetration. Shorten or reroute (step 3) the belt if necessary.
5.5. Recreate tetra elements for all cushion and back foams in respective
components.
5.6. Move the 2D belt elements into the belt components.
5.7. Create the sensor in HyperMesh from Analysis SafetySensors.
5.8. Create the Retractor element from 1D Mass elements with negligible mass.
The retractor should be referenced to the appropriate Belt Id and Sensor ID.
5.9. The Pretensioner should be created from the 1D Mass elements with
negligible mass. The pretensioner should reference to the appropriate Belt ID
and Retractor ID.
5.10. The Slipring element can be created from the 1D Mass elements with
negligible mass referenced to the appropriate Belt ID’s.
5.11. Create the belt nodes set with the 2D belt elements for the belt to dummy
contact.
5.12. Import the front impact velocity (not acceleration) curve in HM. Create
boundary prescribed motion card with the imported velocity curve id. Also,
 update the rigid part id in boundary prescribed motion card with the master
component of the rigid floor.
5.13. Make sure the floor is fixed in all directions i.e CON1 – 7 and CON2 – 7. This
is overwritten by the “Boundary prescribed motion” card when the velocity is
applied in X direction.
5.14. Add front seat rigid plane (if available) to floor Constrained_Rigid_Bodies
card.
5.15. Update single surface contact with front seat rigid plane PID.
5.16. Create contact (node to surface) between belt and seat (master) with the set id
containing all seat components. It should be the same set used in automatic
single surface contact.
5.17. Create contact (surface to surface) between dummy (master) and seat, seat
contact set should include all the seat structure, foam and floor components.
Include the front plane in the seat contact set, if available or dummy to front
plane contact can also be defined separately.
5.18. Create contact (node to surface) between dummy (master) and seat belt using
the belt node set and dummy part set.
5.19. Open the key file in vim editor and write include statements for the dummy
file and interface file and save the key file. Please refer to the picture below
for better understanding.
5.20. Renumber the elements/nodes of the seat if the node/element numbers are
above 1M. Any numbers above 1 million are reserved for dummies.

6. Preparing the front impact setup from a 207/210 model:

Inputs: seat model, morphed foam and dummy.
6.1.
5.21. Import the seat model, floor, front seat planes (if available), front impact
setup and belt.k created above in Hypermesh in this sequence. Front impact
setup model is in kg-mm-ms unit system. It may need to be converted to ton-
mm-sec unit system depending on the program. Refer to Step2 to achieve this
if required. Offset ids should be set to zero before running this file.
6.2. Move the 2D belt elements into the Front impact setup’s 2D belt components.
Delete 1D belt elements from the rerouted belt files. 1D element’s from the
front impact setup file are to be used as these have pretensioner and retractors
defined.
6.3. Attach the 1D belt elements to 2D belt elements.
6.4. Attach the center occupant shoulder belt to retractor part of the center
occupant shoulder belt left over from FMVSS207210 setup. Update the
 section and material property of retractor part of the shoulder belt and delete
unused belt material and property.
6.5. Update the belt nodes set.
6.6. Delete all foam elements. Do not delete the components. Display 40P cushion
seat fabric elements. Find all entities attached to the displayed part. Delete all
elements of cushion seat fabric. This will leave only rigids attaching cushion
seat fabric to the seat structure on the screen.
6.7. Import the morphed foam file. Equivalence the rigids on screen to cushion
seat fabric elements with small tolerance. Check and confirm no free 1D are in
display. Move morphed cushion seat fabric elements to the respective
component.
6.8. Repeat above steps for the remaining seat fabric components.
6.9. Check if the 2D belt elements are penetrating the foam. There should not be
any belt to foam penetration. Shorten or reroute (step 3) the belt if necessary.
6.10. Recreate tetra elements for all cushion and back foams in respective
components.
6.11. Import the front impact velocity (not acceleration) curve in HM. Update
boundary prescribed motion card with the imported velocity curve id. Also,
update the rigid part id in boundary prescribed motion card with the master
component of the rigid floor.
6.12. Make sure the floor is fixed in all directions i.e CON1 – 7 and CON2 – 7. This
is overwritten by the “Boundary prescribed motion“card when the velocity is
applied in X direction.
6.13. Add front seat rigid plane to floor Constrained_Rigid_Bodies card.
6.14. Update single surface contact with front seat rigid plane PID.
6.15. Update master of the Belt2seat surface to surface contact with the set id
containing all seat components. It should be the same set used in automatic
single surface contact.
6.16. Renumber the elements/nodes of the seat if the node/element numbers are
above 1M. Any numbers above 1 million are reserved for dummies.
6.17. Open the key file in vim editor and write include statements for the dummy
file and interface file and save the key file. Please refer to the picture below
for better understanding.

7. Creating interface file

1.1. Edit the interface file for 50%ile, 5%ile or 95%ile dummy as necessary and
renumber the dummy parts in contact as per Table1 (step 2.1).
1.2. Slave set ids referred in the Contact_automatic_Surface_To_Surface card for
each dummy should be updated to set id from the seat model.
1.3. Give a unique name to the interface file if any changes are made to the existing
interface file.
 1.4. Import the final seat key file, dummy and the interface file together in
Hypermesh by selecting “preserve” option while importing. Check all the
contacts.

8. Checks for Frontal Impact

8.1. All the entity ids of the FI setup (PID of 1D, 2D belts and seat plane parts, if
any, velocity curve, nodes and elements) should be less than 1M.
8.2. The front seat plane and floor elements of the FI setup should be added to the
“all seat contact “set and to the Constrained_Rigid_Bodies interface.
8.3. Check the component referred in Boundary prescribed motion card is defined
as master in the Constrained_Rigid_Bodies card.
8.4. Check Belt2seat surface to surface contact has 2D seatbelt components added
to it.
8.5. Check and confirm no CG bracket extra nodes are left in the seat model.
8.6. No unused materials and properties. Do not delete unused rear impact velocity
curve.
8.7. No empty sets. There will be belt_node_sets that are not used. Do not delete
these. These are refered in the interface file.
8.8. Check Load_Body_Z card for curve id.
8.9. Include statements for dummies and interface files are added to the main file.
These need to be added at the top of the file, right after the *Keyword card.
8.10. Import main file in HM and confirm belt to dummy and dummy to seat
contacts are defined correctly. Confirm no penetration between dummy/belts,
dummy/floor, dummy/foam and belt/foam.
 Step-by-Step Modeling Procedure for Rear Impact Setup

1. The only change in the rear impact setup as compared to the front impact
setup is that the slip rings, retractors and pretensioners should be deleted and the
seatbelt 1-D elements should directly be attached to the anchor points.
2. Delete sensor too.
3. The velocity curve for rear impact setup should be assigned to the floor.