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Part 2: Inputchecks
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General Situation
Problem for industrial CRASH/SAFE simulation:
Dataset is very large
Dataset is very complex
Dataset is assembled with components of
Suppliers
Colleagues
Old models (cut and paste)
Dangerous and wrong definitions very difficult to find
Solution:
Improve Solver data check
Solver has to be strict for data check
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V2004: Enhanced Data 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
To avoid stability problems (neg. volume, timestep)
Two tests are implemented:
Position of the middle node
Calculation and check of the Jacobian at different
locations
Examples for bad position of the middle node:
5
10 Node TET Element with bad element
shape
Examples for bad Jacobian
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4 - Node Degenerated HEXA Element
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2D-Element Check:
Internal angle 0 or 180 degree
To avoid numerical problems (core dump, floating
invalid)
Contact algorithm (platform dependent): there is a
risc of 50% to get zero-area triangle in the contact-
algorithm
The error message given by the check:
*** ERROR *** QUAD 1 IS UNACCEPTABLE: TWO CONNECTED EDGES ARE
PARALLEL
Switched by
SHELLCHECK YES(/NO)
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Frame type 1 and 2 used by KJOINT,
JOINT and THLOC
To avoid confusion with frame types
Only Frame type 0 allowed for above entities (just to initialize)
During solution each entity treats and updates his own internal
frame
What happens if the same frame is used for more then one
KJOINT?
To improve DMP performance
Frame type 2 needs very expensive DMP communication even if
the frame is not used
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Wrong analytical strain rate model for
MAT 25, 41
To avoid confusion for users
Solver switch to support analytical law, but no INFO
or WARNING for users in previous version
Was implemented for V2001 solver (global
analytical strain rate switch). Never updated for 2G
solver
10
Material type 301 with failure and zero
distance
Distance needed to predict tension/compression.
Failure will happen only for tensile load
Previous version uses segment normal if distance
is zero. But no info or warning for users.
11
Node ID used for more then one rigid
body COG
This is not allowed and may lead to wrong results.
Never checked in previous 2G versions
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Keyword match with 8 characters
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Airbag Skin and Chamber Orientation
Check
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Airbag Skin and Chamber Orientation
Check (contd.)
Possibilities to check
CrashSafeEditor
Mesh → Normals Orientation → Show
Normals are displayed in the graphical window
Safety → Airbag Definition → Check
Warning message is issued
Solver
Error message in output listing (see below)
BEGINNING OF AIRBAG CHECK
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Airbag Skin and Chamber Orientation
Check (contd.)
Force solver to ignore
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‘
Consequence of non- influence location, ‚hole‘ fixed by
BOUNC)
closed volume
Volume calculation
wrong
Consequently pressure
calculation wrong
Influence on results
depends on location of
elements
Case 2: supporting
structure may be
loaded
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Airbag Closed Volume Check (contd.)
Possibilities to check
Mesh generation tool
Look for free edges
CrashSafeEditor
Safety → Airbag Definition → Check
Warning message is issued
Solver
Error message in output listing (see below)
BEGINNING OF AIRBAG CHECK
*** 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
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Airbag Closed Volume Check (contd.)
AIRBAGCHECK NO
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Metric Topology Check
Approximate mesh
Background
Approximate and reference
mesh need to be topologicaly
identical, i.e. edge numbers
between both meshes must be
consistent
In case of disconnected Reference mesh
meshes, corresponding edges
need to have identical length
If these requirements are
not met, unphysical initial
stresses occur
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Metric Topology Check (contd.)
Possibilities to check
Mesh generation tool
Solver
Error message in output listing (see below)
PARAMETER VALUES :
*** 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
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Metric Topology Check (contd.)
METRICCHECK NO
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Slipring Nodes Coincidence Check
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KW Selection
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