Improving Crashworthiness and

Occupant Safety through virtual

testing with MADYMO

TNO Automotive
 MADYMO

MADYMO: From Concept to Design 2

 Our Mission:

Provide the best value

simulation software for the
passive and active safety
market

MADYMO: From Concept to Design 3

 What is MADYMO?

MADYMO

Multibody FE

Dummy
Utilities
Models

MADYMO: From Concept to Design 4

 MADYMO

Multibody

MADYMO: From Concept to Design 5

Multibody
MADYMO Multibody

• Global method

• Rich joint characterisation

• Rigid and flexible bodies

• Arbitrary surfaces / facets

• Sophisticated contact
options

MADYMO: From Concept to Design 6

Multibody
Joint & Body Characterisation

• Bodies are identified by mass and inertial properties

• Bodies are linked with joints

• Wide range of joints available & properties can be defined in

joints (damping, stiffness, friction…)

• Many surfaces can be attached to bodies:

• Ellipsoid (different degrees) / cylinder / plane
• Meshed surfaces

MADYMO: From Concept to Design 7

Multibody
Multibody Example

P3 child dummy

MADYMO: From Concept to Design 8

Multibody
Multibody Example

Child seat side impact test

application

MADYMO: From Concept to Design 9

Multibody
Flexible Bodies

• A flexible structure has infinite number of degrees of

freedom

• The FEM method uses as many DOF as there are nodes and
about 6 DOF per nodes

• The deformable body method reduces the number of DOF to

only a few by prescribing the main deformation pattern

Hybrid III 5%ile dummy thorax EuroSID-1 rib

MADYMO: From Concept to Design 10

Multibody
Flexible Bodies

Hybrid III 5%ile thorax

Flexible body definition

MADYMO: From Concept to Design 11

 MADYMO

Finite
Element

MADYMO: From Concept to Design 12

FE
MADYMO Finite Element

• Non-linear explicit FE solver

• Full range of elements &

materials

• Large model capability

• Sophisticated airbag options

• Parallel processor support

• Coupling to other explicit FE-

solvers

MADYMO: From Concept to Design 13

FE
Finite Element Example

Headform impact application

MADYMO: From Concept to Design 14

FE
Finite Element Example

US side impact application

MADYMO: From Concept to Design 15

FE
FE Airbag Features

• Multiple Chambers

• Multiple Inflators

• Time-dependant gas composition

• Computational Fluid Dynamic option (CFD)

• Contact algorithm FE / FE & FE / MB

• Efficient
• Stable & Robust

MADYMO: From Concept to Design 16

FE
Finite Element Example

Driver frontal impact application

MADYMO: From Concept to Design 17

 FE
CFD CFD Module

• Developed by Century Dynamics / TNO MADYMO

• Account for non-uniform bag pressure

• More detailed unfolding prediction

• Integrated in MADYMO and easy to use

• Adaptive CFD grid (Langrange-Euler Method)

• Automatic time step control

• Increased run time

MADYMO: From Concept to Design 18

 FE
CFD CFD Application

ITS deployment

Passenger bag deployment

MADYMO: From Concept to Design 19

 MADYMO

Dummy
Models

MADYMO: From Concept to Design 20

Dummy
Models MADYMO Dummy Models

• Mission statement: « To offer a complete range of dummy

models with a varying level of complexity »

• Use the right dummy level complexity for the right

simulation

• Run time shall be as small as possible

• Model requirements
• Realistic / accurate
• Robust / stable
• User friendly / easy to switch level of dummies

MADYMO: From Concept to Design 21

Dummy
Models MADYMO Dummy Models

• Ellipsoid dummy models

• Most run time efficient
• Optimisation and parameter variation study
• Environement with ellipsoids

• Facet dummy models

• New generation multibody dummy models
• More accurate (contacts, geometry, deformable bodies)
• Pay small price in run time

• Finite element dummy models

• Finite element & multibody features implemented
• Simulates local deformations
• To be used in environement with facets / finite elements

MADYMO: From Concept to Design 22

Dummy
Models MADYMO Dummy Modules

Frontal impact dummy module

Tool RB RB / FB FEM / RB
Hybrid III 5%ile
Hybrid III 50%ile
Hybrid III 95%ile
Hybrid III 50%ile standing
Hybrid III 50%ile w/ THOR-LX legs
THOR 50%ile

Hybrid III 50%ile w/ TRID Neck

RID-2
BIORID-2

Side impact dummy module

Tool RB RB / FB FEM / RB
EUROSID-1
EUROSID-2
US SID
US SID w/ Hybrid III head & neck
Bio SID
SID-IIs

MADYMO: From Concept to Design 23

Dummy
Models MADYMO Dummy Modules

Child impact dummy module

Tool RB RB / FB FEM / RB
Hybrid III 10 yrs old
Hybrid III 6yrs old
Hybrid III 3yrs old
Crabi 12 Month
Crabi 6 Month
Q6
Q3
P10
P6
P3
P1 1/2
P3/4

Aviation dummy module

Tool RB RB / FB FEM / RB
Hybrid III 50%ile FAA
Hybrid II

MADYMO: From Concept to Design 24

Dummy
Models MADYMO Dummy Modules

Subsystems module
Tool RB RB / FB FEM / RB
FMVSS 201 Headform
Child headform
Adult headform
Pedestrian legform
Upper legform
3,5 kg Headform
Bodyblock

Barriers
Tool RB RB / FB FEM / RB
FMVSS 214 side impact barrier
WG13 side impact barrier
IIHS SUV side impact barrier
ODB frontal impact barrier
Pole

MADYMO: From Concept to Design 25

 MADYMO

Human
Models

MADYMO: From Concept to Design 26

Human
Models Introduction

• 2 groups of dummies proposed in MADYMO:

• MADYMO Dummies: proven predictive capability
• MADYMO Human Models: improved biofidelity

• Human body models offer:

• Fast implementation of biomechanical research
• Improved biofidelity compared to crash dummies
• Study of injury mechanisms
• Injury criteria based on tissue failure (stress/strain)
• Improved crash protection for various body sizes
• Analysis of different body postures and effects of muscle activity

MADYMO: From Concept to Design 27

Human
Models Overview

• Global human body models

• used for impact loading (pedestrian & occupant) and comfort
• able to predict kinematics, accelerations, forces and torques
• fast CPU

• Detailed segment models

• enable more detailed study
• musculature included
• accurate geometry description
• less fast CPU

• Finite element global human & segment models

• study of injury mechanisms at tissue level
• detailed geometry
• computational costs

MADYMO: From Concept to Design 28

 MADYMO

Utilities

MADYMO: From Concept to Design 29

Utilities
MADYMO Folder

MADYMO: From Concept to Design 30

Utilities
MADYMO Scaler

MADYMO: From Concept to Design 31

Utilities
MADYMO AutoDOE

• Design of Experiments
• Identify effects of design variables on system performance
• Visualise & optimise

• Supporting 5.4 & 6.0(.1)

MADYMO: From Concept to Design 32

Utilities
MADYMO Adviser

• Developed in VITES & ADVANCE project

• Rating predictive quality of models

• Stochastic analysis

SCATTER OF COMPONENT PREDICTION OF STOCHASTIC

RESPONSES IN SYSTEM RESPONSE
Source 1
Source 2
-
-
- i
Source
-
-
- n
Source

NUMERICAL MODEL OF THE

SYSTEM

MADYMO: From Concept to Design 33

Utilities
MADYMO Coupling

MADYMO: From Concept to Design 34

 Top 30+ Key MADYMO Customers

• DaimlerChrysler • Mitsubishi
• VW / Audi / Seat / Skoda • Volvo Truck
• Ford/Jaguar • Autoliv
• GM / Opel / Fiat • Dalphi Metal
• Porsche • Faurecia
• BMW/Rover • UTAC
• Daewoo • Petri
• Hyundai • TRW
• PSA Peugeot Citroën • Breed
• Toyota • Takata
• Nissan / Renault • IDIADA
• Volvo Car • JCI / Lear
• Honda • Boeing, Cessna, ...
MADYMO: From Concept to Design 35
 Conclusions

• Combination FEM - Multibody

• Efficient CPU-usage

• Short modelling time

• Robust and well validated Dummy Models

• Restraint system features

• Utility solutions

• Model optimization tool

MADYMO: From Concept to Design 36