Validation of 2010 Toyota Yaris Sedan Finite Element Model

1. 2010 Toyota Yaris Finite Element Model Validation October 14, 2019

2. 2010 Toyota Yaris Passenger Sedan Real vehicle and FE model of the 2010 Toyota Yaris Sedan The original Finite Element model was developed under a contract with the Federal Highway Administration through the process of reverse engineering. The work was done by the National Crash Analysis Center of the George Washington University and later at Center for Collision Safety and Analysis at George Mason University.

3. 2010 Toyota Yaris Passenger Sedan Model The original Finite Element model was developed in LS-Dyna format. The model and details about its development can be found here, https://www.ccsa.gmu.edu/models/2010-toyota-yaris/. Version 2j of the model was converted to Radioss using Altair HyperCrash 2017.3 with a few minor changes to property and contact options. Foam material updated from LAW38 to LAW70 for robustness. Unit: Ton-mm-s

4. 2010 Toyota Yaris Passenger Sedan Model In general, Radioss best practices are used for property, material, and contact settings. Note that due to the translation from LS-Dyna to Radioss, not all details of the model would be considered best practice if the model was created for Radioss from the beginning. For example, the model contains a shell skin elements on many solid elements. These elements are needed in LS-Dyna for contact. In Radioss, the contact works without these extra shell skin elements. However they are left in model to have the correct model mass.

5. 2010 Toyota Yaris Passenger Sedan Model Connections

6. 2010 Toyota Yaris Passenger Sedan Model Accelerometers 5000001, Left Rear Seat 5000002, Right Rear Seat 5000003, Vehicle C.G. 5000004, Engine Top 5000004, Engine Bottom

7. 2010 Toyota Yaris Passenger Sedan Model Weight and CG Comparisons

8. Toyota Yaris Passenger Sedan Simulation ** Altair Radioss(TM) STARTER 2019.1 ** ** Non-linear Finite Element Analysis Software ** ** from Altair Engineering, Inc. ** • **Build tag: 0972239_1263820191_1060_0062808_10 ** 56Km/h Results from Radioss 2019.1

9. 2010 Toyota Yaris Passenger Sedan Model Model Warnings / Issues --- ELEM/PROP/MAT COMPATIBILITY 13 WARNING(S) | |--- 13 WARNING ID : 340 | ** WARNING IN FORMULATION FLAG (SOLID) DESCRIPTION : -- SOLID COROTATIONAL FORMULATION IS NOT AVAILABLE FOR 4-NODE TETRAHEDRA CHANGE TO NO-COROTATIONAL FORMULATION This warning is caused by a few tetrahedral elements being in the same part as hexahedral elements. These warnings can be ignored.

10. 2010 Toyota Yaris Passenger Sedan Model Model Warnings / Issues -- INTERFACES 1 WARNING(S) | | | |--- 1 WARNING ID : 343 | | ** WARNING : INITIAL PENETRATIONS IN INTERFACE | • Intersections from original LS-Dyna model were not removed. (Ideally the model should not have intersections) • Initial penetrations caused by discretization • Both Issues handled by /INTER/TYPE7 contact options • Fpenmax=0.8, Inacti=6

11. 2010 Toyota Yaris Passenger Sedan Model Model Warnings / Issues --- ELEMENT INITIALIZATION 8 WARNING(S) | |--- 1 WARNING ID : 325 | | ** WARNING : BAD SPRING FRAME DEFINITION (NULL LE| | | |--- 7 WARNING ID : 432 | | ** WARNING IN SPRING ELEMENT SEEMS TO BE MASS AND LENGTH INCONSISTENT ( REFERENCE INERTIA = MASS*LENGTH^2 ) | Both Warnings can be ignored

12. 2010 Toyota Yaris Passenger Sedan Model Model Warnings / Issues --- KINEMATIC CONDITIONS 3 WARNING(S) | | | | | |--- 1 WARNING ID : 312 | | ** INCOMPATIBLE KINEMATIC CONDITIONS IN MODEL | | | |--- 2 WARNING ID : 446 | | ** WARNING IN RIGID WALL | | | Both Warnings can be ignored. Rigid wall slave nodes in other kinematic conditions are automatically removed from the rigid wall.

13. Test data NHTSA test number 5677 – vehicle: 2007 Toyota Yaris Sedan US-NCAP Full frontal impact @ 56 km/h Test results and data available at https://www-nrd.nhtsa.dot.gov/database/VSR/veh/QueryTest.aspx

14. TOYOTA YARIS NCAP 56.3 KM/h Deformation at 70 ms

15. TOYOTA YARIS NCAP 56.3 KM/h

16. TOYOTA YARIS NCAP 56.3 KM/h Mass scaling was used to impose a constant time step of 1e-6. Total mass added = 0.88%

17. TOYOTA YARIS NCAP 56.3 KM/h

18. TOYOTA YARIS NCAP 56.3 KM/h

19. TOYOTA YARIS NCAP 56.3 KM/h

20. TOYOTA YARIS NCAP 56.3 KM/h

21. TOYOTA YARIS NCAP 56.3 KM/h

22. TOYOTA YARIS NCAP 56.3 KM/h

23. TOYOTA YARIS NCAP 56.3 KM/h

24. TOYOTA YARIS NCAP 56.3 KM/h

25. Comment on Engine Acceleration and Stiffness Real motor block FE motor block Deviation between test curves and CAE results for engine accelerations & wall force can be due to the difference between real & FE motor block. The original model had similar differences in the results when compared to test.

26. Summary The Altair Radioss simulation of the 2010 Toyota Yaris in a US-NCAP Full frontal impact @ 56 km/h was verified against NHTSA test number 5677. The results from the Altair Radioss simulation show good correlation to the test results.

27. Model Sensitivity and Robustness Study

28. Sensitivity and Robustness, 2010 Toyota Yaris Model • #---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----| • /RANDOM • # Random-Noise Seed • 1e-006 0.1 • #---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----| • /RANDOM adds random noise by randomly moving nodes a maximum of 1e-6 mm. • Each seed value creates a different random output. • Use seeds from 0.0 to 0.9 by 0.1 increment for 10 runs. Results from robust models will not change dramatically when subject to small changes to the input. Results plotted for the 10 /RANDOM runs and the original base model.

29. TOYOTA YARIS NCAP 56.3 KM/h

30. Time step

31. TOYOTA YARIS NCAP 56.3 KM/h

32. TOYOTA YARIS NCAP 56.3 KM/h

33. TOYOTA YARIS NCAP 56.3 KM/h

34. TOYOTA YARIS NCAP 56.3 KM/h

35. TOYOTA YARIS NCAP 56.3 KM/h

36. TOYOTA YARIS NCAP 56.3 KM/h

37. TOYOTA YARIS NCAP 56.3 KM/h

38. TOYOTA YARIS NCAP 56.3 KM/h

39. Summary The robustness study of the Radioss Yaris model shows that with small changes in the model (1e-6mm) the model remains stable and the results only change slightly.