Abstract:
Hybrid elements that enable coupling effects between SPH particles and FEM solid are disclosed. According to one aspect of the present invention, hybrid elements are configured to facilitate coupling effect of solid element based on finite element method (FEM) and one or more corresponding particles based on smoothed particle hydrodynamics (SPH). Hybrid elements are defined in a computer aided engineering (CAE) grid model as a buffer or interface between the SPH particles and FEM solids. For example, a portion of the grid model comprises SPH particles because the likelihood of enduring large deformation, while the rest of the model comprises FEM solid elements. Hybrid elements are placed between the solids and the particles. Each hybrid element comprises two layers: solid layer and particle layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from a co-pending U.S. Provisional Patent Application Ser. No. 61/246,971, filed on May 26, 2010. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to computer aided mechanical engineering analysis, more particularly to methods and systems for performing time-marching simulation of a structure experiencing large deformations (e.g., car crash or explosion simulations) using a combination of solid elements based on finite element method (FEM) and particles based on smoothed particle hydrodynamics (SPH)), at least one layer of hybrid elements is created between the solid elements and SPH particles to enable coupling effects. 
     BACKGROUND OF THE INVENTION 
     Continuum mechanics has been used for simulating continuous matter such as solids and fluids (i.e., liquids and gases). Differential equations are employed in solving problems in continuum mechanics. Many numerical procedures have been used. One of the most popular methods is finite element analysis (FEA) or finite element method (FEM), which is a computerized method widely used in industry to model and solve engineering problems relating to complex systems such as three-dimensional non-linear structural design and analysis. FEA derives its name from the manner in which the geometry of the object under consideration is specified. With the advent of the modern digital computer, FEA has been implemented as FEA software. Basically, the FEA software is provided with a grid-based model of the geometric description and the associated material properties at each point within the model. In this model, the geometry of the system under analysis is represented by solids, shells and beams of various sizes, which are called elements. The vertices of the elements are referred to as nodes. The model is comprised of a finite number of elements, which are assigned a material name to associate with material properties. The model thus represents the physical space occupied by the object under analysis along with its immediate surroundings. The FEA software then refers to a table in which the properties (e.g., stress-strain constitutive equation, Young&#39;s modulus, Poisson&#39;s ratio, thermo-conductivity) of each material type are tabulated. Additionally, the conditions at the boundary of the object (i.e., loadings, physical constraints, etc.) are specified. In this fashion a model of the object and its environment is created. 
     Once the model is defined, FEA software can be used for performing a numerical simulation of the physical behavior under the specified loading or initial conditions. FEA software is used extensively in the automotive industry to simulate front and side impacts of automobiles, occupant dummies interacting with airbags, and the forming of body parts from sheet metal. Such simulations provide valuable insight to engineers who are able to improve the safety of automobiles and to bring new models to the market more quickly. The simulation is performed in time domain meaning the FEA is computed at many solution cycles starting from an initial solution cycle, at each subsequent solution cycle, the simulation time is incremented by a time step referred to as ΔT. Such simulation is referred to as time-marching simulation. 
     One of the most challenging FEA tasks is to simulate an impact event involving a structure undergoing very large deformation, for example, car crash or explosion simulations. As the modern computer improves, engineers not only wish to simulate the behavior in an impact event with structural failure, they also want to simulate structural behaviors after yielding before total failure from an impact event. However, it is difficult to simulate such phenomena with FEA using solid elements. For example, solid elements representing foam material of a bumper may be squeezed or compressed to become too distorted or squished thereby resulting into zero or negative volume, which causes numerical problem in the simulation (e.g., simulated aborted due to invalid number in a digital computer). 
     To solve the zero or negative volume problem, those failed solid elements are replaced with particles under smoothed particle hydrodynamics (SPH). However, mathematical formulations of the FEM and SPH are different. In order to have particles and solid elements coexist in the same of model, some kind of connections must be established to connect the particles and the solid elements. Prior art approach has been using a tied interface, which rigidly connects certain particles with solid elements. However, this approach generally leads to very unrealistic simulated results due to arbitrary placement of tied interfaces (i.e., rigid links). For example, particles and solid elements are tied together could be reasonable initially. But, as they deform in an unpredictable manner, arbitrary placement of these rigid links might result in a very unrealistic connections. 
     Therefore, it would be desirable to have a more realistic interfaces in a computer aided engineering analysis model such that SPH particles and FEM solids can coexist to avoid problems and shortcomings of the prior art approaches. 
     SUMMARY OF THE INVENTION 
     This section is for the purpose of summarizing some aspects of the present invention and to briefly introduce some preferred embodiments. Simplifications or omissions in this section as well as in the abstract and the title herein may be made to avoid obscuring the purpose of the section. Such simplifications or omissions are not intended to limit the scope of the present invention. 
     Hybrid elements that enable coupling effects between SPH particles and FEM solid are disclosed. According to one aspect of the present invention, hybrid elements are configured to facilitate coupling effect of solid element based on finite element method (FEM) and one or more corresponding particles based on smoothed particle hydrodynamics (SPH). Hybrid elements are defined in a computer aided engineering (CAE) grid model as a buffer or interface between the SPH particles and FEM solids. For example, a portion of the grid model comprises SPH particles because the likelihood of enduring large deformation, while the rest of the model comprises FEM solid elements. Hybrid elements are placed between the solids and the particles. Each hybrid element comprises two layers: solid layer and particle layer. 
     First, the coupling effect of hybrid element is achieved by calculating nodal accelerations, velocities and displacements along with element stresses in the solid layer based on FEM, mapping the calculated such nodal quantities along with element stress state to the particle layer, element stress state includes stress values and current material state of the element (e.g., elastic, plastic, yielding, strain hardening, etc.), calculating internal forces in the particle layer based on SPH, and transferring the internal forces back to the solid layer to calculate nodal forces for next solution cycle. 
     In the following solution cycles, the nodal displacement of solid layers are updated and mapped to the corresponding SPH particles. Internal forces are calculated based on SPH and then transferred back to the solid layer to calculate nodal forces for next solution cycle. 
     According to another aspect of the present invention, a computer aided analysis model can comprise solid finite elements on the perimeter while SPH particles for the rest. Solid elements on the perimeter or edge are configured for facilitating boundary conditions. 
     According to yet another aspect, SPH particles are used for replacing solid elements that have eroded passing its yield limit. The SPH particles can be modeled with a softer material model representing strain hardening effect of the material. 
     Other objects, features, and advantages of the present invention will become apparent upon examining the following detailed description of an embodiment thereof, taken in conjunction with the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects, and advantages of the present invention will be better understood with regard to the following description, appended claims, and accompanying drawings as follows: 
         FIG. 1  is a diagram showing various exemplary hybrid elements according to an embodiment of the present invention; 
         FIGS. 2A-2B  are diagrams illustrating an exemplary structure subject to large deformation which can be numerically simulated with hybrid element, according to an embodiment of the present invention; 
         FIGS. 3A-3D  are several diagrams showing an exemplary sequence of activating coupling effect of hybrid element in accordance with one embodiment of the present invention; 
         FIG. 4  is a diagram illustrating an exemplary stress-strain curve may be used for numerically simulating post-yielding structural behaviors in accordance with one embodiment of the present invention; 
         FIGS. 5A-5C  collectively show a flowchart illustrating an exemplary process of using hybrid elements to numerically simulate post-yielding structural behaviors and large deformation in response to an impulse load, according to an embodiment of the present invention; and 
         FIG. 6  is a function diagram showing salient components of a computing device, in which an embodiment of the present invention may be implemented. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will become obvious to those skilled in the art that the present invention may be practiced without these specific details. The descriptions and representations herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, and circuitry have not been described in detail to avoid unnecessarily obscuring aspects of the present invention. 
     Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the order of blocks in process flowcharts or diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention. 
     Embodiments of the present invention are discussed herein with reference to  FIGS. 1-6 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. 
     Referring first to  FIG. 1 , it is shown a diagram of various exemplary hybrid elements in accordance with one embodiment of the present invention. Hybrid element comprises two parts: solid and corresponding particle layers. Solid layer comprises a solid element based on FEM, while corresponding particle layer comprises one or more particles based on SPH. Solid element includes, is not limited to, hexahedron, wedge and tetrahedron. Hybrid element  110  is a hexahedron with one corresponding particle, element  120  is a wedge element with one particle, and element  130  is a tetrahedron with one particle. Exemplary hybrid elements with more than one particle are shown to have 8 particles for elements  140 , 6 for element  150  and 4 for element  160 . Other numbers of particles can also be implemented according to another embodiment of the present invention. For example, hexahedron with 27 particles (not shown). 
     Coupling effect of hybrid element is achieved by correlating solid layer to the particle layer. Details of internal forces calculation procedure is illustrated in a flowchart shown in  FIG. 4C . For example, solid layer serves as a constraint to particles in the corresponding particle layer. In one embodiment, volume of the solid layer is configured as a domain encompasses the particles. 
       FIGS. 2A-2B  shows a sequence of an object (i.e., a projectile in form of rigid ball)  210  contacting a structure (i.e., a plate partially shown as a grid model)  220  with a relative high velocity (indicated by arrow  215 ) thus an impulse load. Part of the structure subject to the impulse load is modeled with elements  225  (shown as dotted line). Elements  225  can be modeled with FEM solid elements initially. When the impact from the ball  210  impacts the plate  220 , elements  225  may experience failure or yielding (see  FIG. 4  and corresponding descriptions for definition of material failure and yielding). The failed elements are replaced with SPH particles to continue the simulation. Since SPH particles and FEM solid elements use different formulations, an interface in forms of hybrid elements are created between the SPH particles and FEM solid elements to enable coupling effect. 
     To further demonstrate the above example,  FIGS. 3A-3D  shows a sequence of plan views of the structure (plate  220 ). At the outset, the plate  220  is shown as all solid elements in  FIG. 3A . Next, in  FIG. 3B , the center solid element fails and is replaced with a SPH particle (shown as a shaded circle with a center dot). This may be caused by the projectile/ball  210  makes a hard contact with the plate  220 . At least one layer of hybrid elements (shown as shaded elements) are created as an interface for coupling effect between the SPH particle and solid elements. Then more elements around the center element fail and are replaced with SPH particles in  FIG. 3C . As can be seen, interface of hybrid elements is dynamically adjusted to be always located between the SPH particles and the solid elements. 
     Furthermore, hybrid elements can be placed on the boundary of a CAE model with SPH particles in the rest of the model. The configuration shown in  FIG. 3D  demonstrate this aspect of the present invention. 
       FIG. 4  shows an exemplary a stress-strain curve, which may be used for determining post-yielding structural behaviors in a structure, according to one embodiment of the present invention. The curve  400  has a vertical axis representing stress  402  and a horizontal axis for strain  404 . Material has two regions: elastic  406  and plastic  408 . Plastic region  408  is further divided into three categories: yielding  424 , strain hardening  426  and necking  428 . At the top end of the elastic region of the stress-strain curve  400  is a yielding point  414 , to which the yielding stress corresponds. The ultimate stress corresponds to the ultimate strength point  416 , while the fracture or failure stress to the failure location  418 . According to one embodiment, FEM solid elements are used for modeling the elastic behavior of the material. As soon as the material goes beyond yielding, SPH particles are generated to replace the solid elements. The replaced SPH particles are modeled with softer material model so that strain hardening effect can be simulated more realistically. 
     Referring now to  FIG. 5A , it is shown a flowchart illustrating an exemplary process  500  of using hybrid elements to numerically simulate post-yielding structural behaviors and large deformation in response to an impulse load, according to an embodiment of the present invention. Process  500  is preferably implemented in software. 
     Process  500  starts by defining a computer aided analysis grid model (e.g, a FEM grid model) of a structure (e.g., car, airplane) at step  502 . The grid model includes one or more hybrid elements representing part of the structure most likely subject to large deformation, for example, bumper of a car in a crash simulation. The grid model is used in a time-marching simulation. Next, at step  504 , all elements and parameters are initialized in the time-marching simulation at the outset (i.e., time equal to zero, or first solution cycle). Then, process  500  checks whether coupling effect of hybrid element has been activated in decision  506 . If “no”, process  500  moves to step  508  to conduct simulation by treating hybrid elements as if they are solid elements under FEM. More details for step  508  are described in  FIG. 5B  and corresponding descriptions. In other words, the time-marching simulation is conducted using FEM if the coupling effect is not activated. Otherwise, if “yes”, process  500  moves to step  510  by conducting time-marching simulation with hybrid elements to include coupling effect.  FIG. 5C  and associated descriptions are for step  510 . 
     Process  500  moves to step  516  by incrementing simulation time of the next solution cycle. Then, in decision  518 , it is determined whether the time-marching simulation has ended. For example, checking the simulation time against a predetermined total simulation time. If not, process  500  moves back to decision  506  to repeat the rest of steps for next solution cycle until decision  518  becomes true. Process  500  ends thereafter. 
       FIG. 5B  shows further details of step  508 . At step  522 , process  500  obtains nodal accelerations, velocities and displacements of each element including hybrid elements. In one embodiment, the nodal quantities are obtained in explicit solver under FEM (e.g., f=m×a, where “f” is nodal force, “m” is nodal mass and “a” is nodal accelerations). Next, at step  524 , element internal forces are calculated in accordance with solid formation under FEM. Finally, at step  526 , nodal forces for next solution cycle can be calculated to include contribution from element internal forces. Any given node may receive contribution from all connected elements. 
       FIG. 5C  shows additional details of step  510 . At step  532 , process obtains nodal quantities (i.e., nodal accelerations, velocities and displacements, and element stress state) in the solid layer of the hybrid element substantially similar to step  522  under FEM. Next, at step  533 , the obtained nodal quantities and element state are mapped to the corresponding particle layer in the beginning of the coupling. Then in the following cycles only nodal displacements are mapped to the corresponding particle layer. Displacements of the solid layer are updated and mapped to corresponding SPH particles as constraints. In other words, SPH particles are restricted by the nodal displacements calculated based on FEM. Internal forces are calculated in the particle layer and transferred to the solid layer for calculating nodal forces based on FEM for next solution cycle. In other words, the internal forces are obtained using SPH, the internal force calculations in the solid layer is suspended in the hybrid element during these exchanges. Element stress state includes at least the stress values calculated for that element. Additionally, element stress state includes the current state of the element in an element stress state history variable. This variable or other equivalent means is used for tracking the state of the element throughout the time-marching simulation. In other words, post-yielding state of an element may be determined from the history variable of that element. 
     Internal force of the hybrid element is then calculated at particles in the corresponding particle layer based on SPH formulation at step  534 . Next, at step  535 , the internal forces are transferred back to the solid layer. In other words, element internal forces of the solid layer are substituted with those calculated from the particles in the corresponding particle layer. Finally, at step  536 , nodal forces for next solution cycle are calculated including contribution of element internal forces substantially similar to step  526 . 
     According to one aspect, the present invention is directed towards one or more computer systems capable of carrying out the functionality described herein. An example of a computer system  600  is shown in  FIG. 6 . The computer system  600  includes one or more processors, such as processor  604 . The processor  604  is connected to a computer system internal communication bus  602 . Various software embodiments are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the relevant art(s) how to implement the invention using other computer systems and/or computer architectures. 
     Computer system  600  also includes a main memory  608 , preferably random access memory (RAM), and may also include a secondary memory  610 . The secondary memory  610  may include, for example, one or more hard disk drives  612  and/or one or more removable storage drives  614 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive  614  reads from and/or writes to a removable storage unit  618  in a well-known manner. Removable storage unit  618 , represents a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive  614 . As will be appreciated, the removable storage unit  618  includes a computer usable storage medium having stored therein computer software and/or data. 
     In alternative embodiments, secondary memory  610  may include other similar means for allowing computer programs or other instructions to be loaded into computer system  600 . Such means may include, for example, a removable storage unit  622  and an interface  620 . Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an Erasable Programmable Read-Only Memory (EPROM), Universal Serial Bus (USB) flash memory, or PROM) and associated socket, and other removable storage units  622  and interfaces  620  which allow software and data to be transferred from the removable storage unit  622  to computer system  600 . In general, Computer system  600  is controlled and coordinated by operating system (OS) software, which performs tasks such as process scheduling, memory management, networking and I/O services. 
     There may also be a communications interface  624  connecting to the bus  602 . Communications interface  624  allows software and data to be transferred between computer system  600  and external devices. Examples of communications interface  624  may include a modem, a network interface (such as an Ethernet card), a communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communications interface  624 . The computer  600  communicates with other computing devices over a data network based on a special set of rules (i.e., a protocol). One of the common protocols is TCP/IP (Transmission Control Protocol/Internet Protocol) commonly used in the Internet. In general, the communication interface  624  manages the assembling of a data file into smaller packets that are transmitted over the data network or reassembles received packets into the original data file. In addition, the communication interface  624  handles the address part of each packet so that it gets to the right destination or intercepts packets destined for the computer  600 . In this document, the terms “computer program medium”, “computer readable medium”, “computer recordable medium” and “computer usable medium” are used to generally refer to media such as removable storage drive  614  (e.g., flash storage drive), and/or a hard disk installed in hard disk drive  612 . These computer program products are means for providing software to computer system  600 . The invention is directed to such computer program products. 
     The computer system  600  may also include an input/output (I/O) interface  630 , which provides the computer system  600  to access monitor, keyboard, mouse, printer, scanner, plotter, and alike. 
     Computer programs (also called computer control logic) are stored as application modules  606  in main memory  608  and/or secondary memory  610 . Computer programs may also be received via communications interface  624 . Such computer programs, when executed, enable the computer system  600  to perform the features of the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor  604  to perform features of the present invention. Accordingly, such computer programs represent controllers of the computer system  600 . 
     In an embodiment where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system  600  using removable storage drive  614 , hard drive  612 , or communications interface  624 . The application module  606 , when executed by the processor  604 , causes the processor  604  to perform the functions of the invention as described herein. 
     The main memory  608  may be loaded with one or more application modules  606  (e.g., FEM and/or SPH application module) that can be executed by one or more processors  604  with or without a user input through the I/O interface  630  to achieve desired tasks. In operation, when at least one processor  604  executes one of the application modules  606 , the results are computed and stored in the secondary memory  610  (i.e., hard disk drive  612 ). The status of the analysis is reported to the user via the I/O interface  630  either in a text or in a graphical representation upon user&#39;s instructions. 
     Although the present invention has been described with reference to specific embodiments thereof, these embodiments are merely illustrative, and not restrictive of, the present invention. Various modifications or changes to the specifically disclosed exemplary embodiments will be suggested to persons skilled in the art. For example, whereas the exemplary structure subject to large deformations has been shown and described as a projectile impacting a plate, other structures under an impulse load can be numerically simulated with the claimed method of the present invention, for example, bumper of an automobile in a car crash. Additionally, whereas solid elements have been shown and described as hexahedron, wedge and tetrahedron, other types of solid elements can be used instead, for example, pentahedron. In summary, the scope of the invention should not be restricted to the specific exemplary embodiments disclosed herein, and all modifications that are readily suggested to those of ordinary skill in the art should be included within the spirit and purview of this application and scope of the appended claims.