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LS-DYNA Model Development of the THOR-M Crash Test Dummy

Developments on the THOR dummy over the past years resulted in the THOR-M version which is foreseen for introduction into regulatory and Consumer tests in the 2020 timeframe. NHTSA considers to use the THOR-M dummy in an angled impact test while Euro NCAP includes plans for the development of a frontal barrier test with THOR-M in their roadmap for 2020. To support the development of restraint systems for both test configurations Humanetics is developing a Finite Element model of the THOR-M dummy. This paper presents activities which results in the version 1.0 model as well as an outlook to future model releases. Geometry information was obtained from 2-D drawings and CAD models of individual parts. Like for a physical dummy the individual parts were assembled into a full model by means of quasi static simulations. The geometry of the resulting THOR-M model was then checked against laser scans of available ATD’s and refined where needed. Detailed mass and inertial properties are obtained from CAD models and mass measurements of physical parts. The model connectivity and structural integrity are verified against the hardware. The model represents the latest features in the hardware like the SD3 shoulder and the latest foot design. The THOR-M dummy is more biofidelic than existing dummies like HIII and ES. Combined with potentially higher and more complex, out of plane, loadings resulting from angled impact and frontal barrier test procedures it is to be expected that larger deformations occur in the THOR-M. This makes the development of the THOR-M material models more challenging. The possible loading and deformation patterns of relevant materials, as can be expected in future testing, have been identified and analyzed from available full scale test results. Material tests (a total number of 210 tests for about 35 materials) were defined and performed to collect the essential information needed to describe the characteristics of the materials for applicable deformation modes and its severities. The coupon tests have been simulated to verify the material cards. Furthermore the performance of the material models is being verified in additional material, component, sub-assembly and full dummy tests which undergo more complex deformation patterns. The material modelling approach proves to show excellent stability in an extensive robustness test program and in the first user applications. The THOR-M model is validated against a first set of validation load cases which shows promising initial correlation. Further validation tests will be executed in this project to prove overall correlation to nominal hardware response in complex but relevant load cases. The THOR-M model represents all available hardware instrumentation.