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1、MATERIAL CONSIDERATIONS IN DUMMY DEVELOPMENT(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryContentsIntroductionHuman materialsEarly generation dummy materialsMaterials and examples of application(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryCr
2、ash Test DummiesDummies are mechanical surrogates of the human body used to evaluate injury risk in dynamic testingVital link between impact loading and occupant injury riskBased on biomechanical knowledge and real-world injury prioritiesNeeds to represent mechanical behavior of humans under highly
3、dynamic and non-linear impact loadings occurring in vehicle crashes Introduction Crash Test Dummies(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryIntroductionDummy design criteriaAnthropometryoGeometry,mass&distribution,CoG,Inertia,densityBiofidelityoPMHS/Volunteer/Animal
4、 testing+HBM simulationsoKinematics,acceleration,range of motionoMechanical,deformation,contacts,force deflectionCertification/calibrationoControl of dummy output at specific input impactDurabilityoExtreme loading conditions,overloadHandlingoDay to day use,assembly,disassembly,maintenance,wiringInju
5、ry prediction&InstrumentationoAccidentology,abbreviated injury scale,PMHS testing,injury threshold valuesRepeatability/Reproducibility R&RoConsistency of material properties,manufacturing process control,quality proceduresSensitivityoRange of application,test conditions,injury mechanism(20151112)201
6、3 Humanetics Innovative Solutions Inc.Confidential&ProprietaryIntroductionConsiderations for material usageDummy development and acceptance is long term processoTHOR started early eightiesoWorldSID started late ninetiesOnce accepted dummies for long period in regulations e.g.HIII dummyRisk for mater
7、ial discontinuation over development and use period oREACHoRisk for suppliers stopping deliveryRelatively small batches for dummy supplyIncreasing requirements on biofidelityoMore compliant dummiesoStricter requirements on R&RSensitivity to environmental parametersoTemperature oHumidity(20151112)Mec
8、hanical functionsoSupportoProtectionoMechanical structure for movementMaterialoComposite largely consisting of calcium phosphate StructureoCortical(dense)bone oTrabecular(spongy)boneoExtremely light weight structureProperties relevant for dummiesoDensityoYoungs modulusoStress-strainoElastic limitoNo
9、ne linear elasticoEnergy dissipationComparative engineering materials?Human materialBone 2013 Humanetics Innovative Solutions Inc.Confidential&Proprietary(20151112)Mechanical functionsoMechanical connectionoIntroducing elasticityoShock absorption jointsMaterialoFibers in extracellular matrixStructur
10、eoElastic cartilageoHyaline cartilageoFibro cartilageProperties relevant for dummiesoDensityoYoungs modulusoStress-strainoElastic limitoNone linear elasticComparative engineering materials?Human materialCartilage 2013 Humanetics Innovative Solutions Inc.Confidential&Proprietary(20151112)Mechanical f
11、unctionsoActuators responsible for e.g.Maintenance of and changes in postureMovement of internal organs oElastic surface layerMaterialoProtein filaments that slide past one another producing a contractionStructureoSoft tissueoSkeletal muscleoSmooth muscleoCardiac muscleProperties relevant for dummie
12、soDensityoCompression modulusHuman materialBone 2013 Humanetics Innovative Solutions Inc.Confidential&Proprietary(20151112)Mechanical“functions”oAdded masso(nonlinear)StiffnessoDampingBasic groupsoAbdominal organs including liveroBrainoLungMechanical properties relevant for dummiesoDensity(mass dist
13、ribution)oCompressive stress-strain relationoViscous effects and dampingHuman materialOrgans 2013 Humanetics Innovative Solutions Inc.Confidential&Proprietary(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryIn the beginning 70-tiesExample Oliver and PinocchioPredecessors of
14、 TNO-10 and child dummiesMaterials usedoWoodoLeatheroConstruction steeloRubberoPolymerExample Oliver headoPolymeroBucket used as mouldoDrilled holes to tune mass(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryEarly Generation Dummies 80-tiesHybrids,US-SID AluminiumoCasting
15、s for skull and pelvis structureoHigh tensile alloy steeloRibs,load cells,cables neck and spineConstruction steelolong bones,spinePVCoSolid molding head skinoRotation molding skin flesh componentsoPVC foam flesh componentsoDamping linersRubberoNeck and spine(20151112)2013 Humanetics Innovative Solut
16、ions Inc.Confidential&ProprietarySteel and aluminium Basic differences with human materialsIn a human the majority of the mass is in the soft tissue:Human bone 18%of thigh mass*Early dummies most of mass in structural parts:EuroSID-1 bone 70%thigh massMass spikes in case of hard contactNo damping/hy
17、steresisoRibs lined with polymer damping material are highly temperature sensitiveoAluminium skulls have difficulty in handling high frequencies due vibrations,oscillationsExample glass impactHigh stiffnessoNo human like bending/compression in bonesoExample:Leg and thigh deformation pedestrian impac
18、t*Dempster,Space requirements for the seated operator,WADC Technical Report 55-159,Wright Patterson Air Force Base,OH:Wright Air Development Center,1955 page 201.Mass of human organs in the leg and distance to the floor0.00.10.20.30.40.50.60.70.80.91.00100200300400500600700800Distance to the floor m
19、mOrgan mass kgbone mass kgflesh and skin mass kgtotal mass 2 membersFE model Pedestrian Leg ImpactorHuman leg model(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryAlternative:ThermosetpolymersMechanical propertiesoBetween hard rubbers and engineering plastics oChemistry al
20、lows component biomechanical response tuningoTuning of properties via material compositionoFibre reinforcement for additional strength and stiffnessoEnergy dissipation under loading,hysteresisDensityoSame range as human materialoAddition of ballast material for density increaseManufacturingoIn soft
21、tools(silicon rubber)oComplex shapes oExcellent for low quantity and prototypingoAllows local metal insertsoIntegration of functions(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryMaterial Stiffness Trends of ATD DesignsCompliance of ComponentsDummy TypeHybrid IHybrid IIHy
22、brid IIITHORNext gen thoraxQ(20151112)11/16/2015FLEX-PLI/TRL-PLIExample:legformimpactor(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryWorld-wide Government ProgramsEuropean Community Regulation on chemicals and their safe use dealing with Registration,Evaluation,Authoriza
23、tion and Restriction of Chemical substancesJapan Green ProgramUnited Stated Environmental Protection AgencyIssue when considering long development and in-use times of dummiesBanning use of components like Ureol applied in thermosets for various dummiesNeed for adequate material replacement process(2
24、0151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryMaterial Replacement ApproachMaterial selection Evaluating replacement alternativesDOE Quasi static tests on material coupons or parts Dynamic impact tests on material coupons or partsDynamic impact test Certification and/or dy
25、namic impact testDurability Test Repeats of impact tests on parts or dummy(durability)Reporting Report Findings in a Tech Bulletin(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryReplacement materialCheck on possibilities for tuningAvg.Force(N)TuningNew Vs OldReplacement Ma
26、terialOriginal Material(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietarySled testing(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietarySled testing(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryTemperature sensitivity mate
27、rials Example HIII chest deflection 5%/C(20151112)2013 Humanetics Innovative Solutions Inc.Confidential&ProprietaryExample material supply discontinuationSupplier of HIII rib damping material stopped production of the material per 2010Alternative formulations found in 2011oLower durability(Tech Bull
28、etin June 2012)oHigher hysteresis in low speed test requiring update of hysteresis corridorsNew improved material introduced in 2012oBehavior identical to original material in low and high speed testsoAverage thickness close to original materialoGood durabilityoMaterial currently appliedoSee service
29、 bulletin December 2012(20151112)2013 Humanetics Innovative Solutions,Inc.This presentation is the proprietary property of Humanetics Innovative Solutions,Inc;a registered company in Plymouth,Michigan,USA.The report includes confidential information.Disclosure,use,copying,or distribution of this information without the written authorization of Humanetics Innovative Solutions is prohibited.Thank you!(20151112)