ANALYSIS AND MODELING OF

DUCTILE CAST IRON

BRACKETS IN CRASH
CONDITIONS USING RADIOSS
How to predict the right cast part behavior and a correct rupture level ?
Jerome LAGRUT

Page 1

EHTC OCTOBER 2007

SYNOPSIS

Project presentation
Brackets and expected behavior
Material modeling and identification
Validation
Crash calculation with the new models

Project conclusions and outlook

Jerome LAGRUT

Page 2

EHTC OCTOBER 2007

SYNOPSIS

Project presentation
Brackets and expected behavior
Material modeling and identification
Validation
Crash calculation with the new models

Project conclusions and outlook

Jerome LAGRUT

Page 3

EHTC OCTOBER 2007

BRACKETS AND EXPECTED BEHAVIOR

Jerome LAGRUT

Page 4

EHTC OCTOBER 2007

BRACKETS AND EXPECTED BEHAVIOR

back

back

back

suspension

suspension

Bottom attached to the chassis via the multifunction bracket

Jerome LAGRUT

Page 5

EHTC OCTOBER 2007

BRACKETS AND EXPECTED BEHAVIOR

Crashworthiness requirements
147
kN
98 kN

Break

Remain
1.96
29.4kN
kJ/T

Barrier
Test

44
29.4
kJ kJ

30 km/h

BOF10

ECE 29

Jerome LAGRUT

Page 6

EHTC OCTOBER 2007

SYNOPSIS

Project presentation
Brackets and expected behavior
Material modeling and identification
Validation
Crash calculation with the new models

Project conclusions and outlook

Jerome LAGRUT

Page 7

EHTC OCTOBER 2007

GS50 CAST MATERIAL

Heterogeneous material
Graphite nodules
Ferrite + pearlite + cementite

core
Mid
zone

Heterogeneous cooling
skin

Different crystals in geometrical zones

Different carbon solidification

Only one numerical model

Jerome LAGRUT

Page 8

EHTC OCTOBER 2007

CAST MATERIAL MODELING

Bracket

Meca
Bracket

Rubber
Bracket

tension
shear

compression
Triaxiality phenomena must be taken into account
Jerome LAGRUT

Page 9

EHTC OCTOBER 2007

CAST MATERIAL MODELING

Needs

Elastic behavior

Numerical model in RADIOSS

Behavior model
Law2
Law36
Law48
Failure criterion
Failure strain/stress
Johnson-Cook
Bao-Xue-Wierzbicki

Hardening
Strain rate dependency
Triaxiality behavior
Realistic failure

Jerome LAGRUT

Page 10

EHTC OCTOBER 2007

TESTS FOR MATERIAL IDENTIFICATION

tensile

torsion

compression

1 and 10 rpm
QS to 10

QS

s-1

Behavior identification

Failure identification

-hardening

-stress state influence

-strain rate effect

-strain rate effect

Jerome LAGRUT

Page 11

EHTC OCTOBER 2007

TESTS FOR MATERIAL IDENTIFICATION

Test matrix

2 GS50 castings (for robustness)

36 tests between 10-4 s-1 and 10-1 s-1

traction

2 GS50 castings (for robustness)

14 tests between 10-1 s-1 and 10 s-1

High speed traction

2 GS50 castings (for robustness)

16 tests between 1 rpm and 10 rpm

torsion

2 GS50 castings (for robustness)

16 tests

compression

82 tests on 2 different castings

Jerome LAGRUT

Page 12

EHTC OCTOBER 2007

FAILURE

BEHAVIOR

RADIOSS MODEL

Jerome LAGRUT

Law2

Johnson-Cook
criterion

= a + b p

fail

&
1 + c ln
&

pressure
D3

&

eq

1 + D4 ln
= D1 + D2 e
&

Page 13

EHTC OCTOBER 2007

BEHAVIOR IDENTIFICATION

= a + b p

Law2

&
1 + c ln
&

1.1

Johnson-Cook behavior model identification

600

1.08

500
Normalized stress

stress (MPa)

1.06

400
300

U311-05
U315-05
U314-05
U320-05

200

1.04

1.02

100

stress at 5% strain
stress at 10% strain
stress at 15% strain

0
0

0.05

0.1

0.15

0.2

0.25

0.98
0.00001

plastic strain

Jerome LAGRUT

0.0001

0.001

0.01

0.1

Strain rate

Page 14

EHTC OCTOBER 2007

BEHAVIOR IDENTIFICATION

= a + b p

&
1 + c ln
&

700

600

500

U 3 11 - 0 5
U 3 14 - 0 5
U 3 15 - 0 5

400
Stress

U 3 20 - 0 5
U 4 01 - 0 .5
U 4 15 - 0 .5
U 4 18 - 0 .5
U 4 19 - 0 .5

300

J o h n s o n -C o o k

200

100

0
0

0 .05

0 .1

0 .15

0 .2

0 .2 5

Pla s tic S tra in

Matlab optimization
Jerome LAGRUT

Page 15

EHTC OCTOBER 2007

BEHAVIOR IDENTIFICATION

= a + b p

&
1 + c ln
&

1.1

1.08

C-linear slope
Normalized stress

1.06

1.04

eps_0

1.02

stress at 5% strain
stress at 10% strain
stress at 15% strain

0.98
0.00001

0.0001

0.001

0.01

0.1

Strain rate

Jerome LAGRUT

Page 16

EHTC OCTOBER 2007

FAILURE IDENTIFICATION
Johnson-Cook
fail
criterion

pressure
D3

&

eq

1 + D4 ln
= D1 + D2e
&

Engineering failure strain

30

D4-linear slope

Failure strain (%)

25

D4

20

eps_0
15
Failure level

10
0.00001 0.0001

Jerome LAGRUT

0.001

0.01
0.1
Strain rate (s-1)

10

100

Page 17

EHTC OCTOBER 2007

FAILURE IDENTIFICATION
fail

pressure
D3

&

eq

1 + D4 ln
= D1 + D2 e
&

Mean JCC

1.6
Johnson Cook Criterion

1.4

Tensile
Shear

D1

1.2

Failure strain

Compression

D2

0.8
0.6

D3

0.4
0.2

D4

Old criterion

0
-0.666

-0.333

0.333

0.666

Eps_0

Triaxiality factor (the one use d in RADIOSS computation = 1*re al one )

Jerome LAGRUT

Page 18

EHTC OCTOBER 2007

FAILURE IDENTIFICATION
fail

=
*

pressure

Jerome LAGRUT

eq

pressure
D3

&

eq

1 + D4 ln
= D1 + D2e
&

Tr ( )

VM

mp
o
C

i on
s
re s

Shear
Tr a
cti
on

* =

pressure

* =

pressure

eq
eq

=
=

Tr ( )

VM
Tr ( )

VM

xx
1
= 3 =
xx 3
=

VM

=0

xx
pressure Tr ( )
1
*
3
=
=
=
=
eq
VM
xx
3
Page 19

EHTC OCTOBER 2007

SYNOPSIS

Project presentation
Brackets and expected behavior
Material modeling and identification
Validation
Crash calculation with the new models

Project conclusions and outlook

Jerome LAGRUT

Page 20

EHTC OCTOBER 2007

VALIDATION LOOP : SAMPLES

80000

70000

60

50

60000

Force (N)

50000

40

303
304

30

305
306

10-2
10-4

20

10
10-1

401
402

10

404
405

10-3

40000

30000

307

406

0
0

20000

90

180

270

360

450

540

Srie1

-10

10000

-20

0
0

10

15

20

Displacement (mm)
120000
70000

100000

W413 (5mm/mn)
W414 (5mm/mn)

60000

80000

W415 (1mm/mn)
W412 (1mm/mn)

50000

60000

W411
W312 (5mm/mn)

30000

40000

W314 (5mm/mn)
W315 (1mm/mn)

20000

20000

W311(1mm/mn)
W303
Srie11

Strength

40000

10000

0
0

10

0
0

10

Displacement

Jerome LAGRUT

11

12

13

14

15

16

17

18

-20000

Page 21

EHTC OCTOBER 2007

VALIDATION LOOP : SUBSYSTEMS

Achieved regularly on brackets

Represent real load cases

Jerome LAGRUT

Page 22

EHTC OCTOBER 2007

SYNOPSIS

Project presentation
Brackets and expected behavior
Material modeling and identification
Validation
Crash calculation with the new models

Project conclusions and outlook

Jerome LAGRUT

Page 23

EHTC OCTOBER 2007

CRASH CALCULATIONS
Simulations on complete vehicles

Good correlation with tests !

Jerome LAGRUT

Page 24

EHTC OCTOBER 2007

SYNOPSIS

Project presentation
Brackets and expected behavior
Material modeling and identification
Validation
Crash calculation with the new models

Project conclusions and outlook

Jerome LAGRUT

Page 25

EHTC OCTOBER 2007

CONCLUSIONS AND OUTLOOK

Answer to calculation needs

Better modeling better prediction
Only available for RADIOSS V5
Methodology to identify behavior and failure of ductile
cast iron

A model is only correct close to the range it was

identified on (Material, SR range, configurations)
Jerome LAGRUT

Page 26

EHTC OCTOBER 2007

ACKNOWLEDGEMENTS

Jerome LAGRUT

Orel Fournier (Ecole Polytechnique)

Volvo laboratory department
CETIM
La Fonte Ardennaise

Page 27

EHTC OCTOBER 2007