A Development Process for Creating Finite-Element Models of Crash Test Dummies Based on Investigations of the Hardware.

Crash test dummies act as a surrogate for humans in high loading conditions. Their anthropometry and properties have been retrieved in extensive research in the field of biomechanics. Accessibility to technical drawings and other specifications of crash test dummies is normally limited to theirmanufacturers. Furthermore, the hardware is affected by manufacturing tolerances, especially the complex shapes of dummies. Nevertheless reliable numerical simulation models are needed to support virtual engineering processes. In order to build up a Finite-Element-Method (FEM) simulation model,a process was defined to retrieve all relevant data by investigation of the hardware. The BIORID-II dummy was chosen to demonstrate this process. In a first step, it was necessary to capture the geometry of the BIORID-II.It is important to identify not only the exact geometry of every single part but also the assembly to know about the initial position. Different measuring methods such as optical 3D scanners, photographic analysis and manual measuring methods were used for this purpose. Based on these geometrical data FEM meshes were created. In a next step, functional characteristics of subassemblies were analyzed by separate testing. In case of the BioRID II - Dummy, the behavior of different springs, dampers and cables were determined, especially the characteristic of the materials. In the spine ofthe dummy several pre-stressed elements made of hyper-elastic materials exist, therefore not only the behavior of the material but also the initialcondition were important. For validation purposes, three different tests have been used: the prescribed calibration test, an additional sled test, both with the torso only, and a sled test with a car seat and the whole dummy. The numerical simulations showed good accordance in comparison to both hardware tests and component tests. The calibration test was passed. Thefull text of this paper may be found at: http://www-nrd.nhtsa.dot.gov/pdf/esv/esv21/09-0368.pdf For the covering abstract see ITRD E145407.