Development of the THOR-5F crash test dummy FE model and synergy with design support

Shah, Chirag; Feng, Zhaoying; Hu, George; Jagadish, Renuka; Wang, Jerry; Mahadevaiah, Jagadish; Prasad, Renuka; Shelat, Chintan; Mohan, Pradeep

Affiliations

¹Humanetics Innovative Solutions, Inc., USA

²Humanetics Innovative Solutions India Private Limited, India

Abstract

Alongside the hardware development of the THOR (Test Device for Human Occupant Restraint) 5th percentile female crash test dummy in cooperation with NHTSA, the development of the THOR 5th FE model is also well underway. The THOR 5th is an advanced small female crash test dummy and referred hereafter as THOR-5F. The main objective of the current paper is to describe detailed FE model development and biofidelity evaluation of the THOR-5F FE model. The paper also presents design support using the FE modeling for the THOR-5F ankle joint hardware design.

As with all FE models, geometry, material modeling and structural connectivity are of focus when developing the THOR-5F FE model. All the instrumentation and sensors are accurately realized in the model. Furthermore, it has first-hand access to the physical counterpart that allows the model to incorporate the latest hardware design features. The THOR-5F FE model is then evaluated against over 20 biofidelity tests from head to toe for functionality and performance evaluation. The current paper presents selected biofidelity test validations.

The THOR-5F FE model showed promising functionality and performance for the evaluated biofidelity validation cases. Concurrent development of the FE model enabled the hardware team a possibility to evaluate the concept design aimed to meet the biofidelity requirements, reduce design cycle and reduce production cost by performing the FE analysis prior to manufacturing hardware parts. This paper illustrates in particular the ankle design improvement in the THOR-5F hardware supported by the FE analysis. Such synergy between hardware and FE complements each other for the improved hardware design and better model predictability and performance.

The first FE model of the THOR-5F will be released in the 3rd quarter of 2017. This highly anticipated model will consist of a state-of-the-art mesh and appropriate connectivity, instrumentation, basic material models and preliminary validations to all available biofidelity tests to ensure the model functionality. The model will be validated rigorously against additional test load cases as they become available.

Links

URL: http://indexsmart.mirasmart.com/25esv/PDFfiles/25ESV-000244.pdf

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