Abstract:
This study investigates the key factors influencing the accuracy of a Finite Element simulation of a destructive Roll-Over Protective Structure (ROPS) test on a Volvo cab, with the goal of replacing physical tests with reliable numerical models. Using the explicit finite element code LS-DYNA, a detailed model of the cab was created with a combination of shell and solid elements and subjected to simulated loading conditions that replicate the physical ROPS test procedure. A comprehensive sensitivity analysis was performed to evaluate how different Finite Element modeling parameters affect the simulation's prediction of force-deflection and energy absorption curves when compared to experimental test data. The investigation focused on several critical FEA inputs: the choice of material model, specifically comparing isotropic (*MAT_PIECEWISE_LINEAR_PLASTICITY) and kinematic hardening models; the inclusion of strain-rate effects; the modeling of heat-affected zones from welding; mesh density and element type; and the formulation of the contact algorithm between the loading platen and the cab structure. The results demonstrated that accurately capturing the post-yield material behavior, particularly strain hardening, and the proper definition of contact were the most significant factors, while the effects of welding and strain rate were found to be less critical for this specific quasi-static test simulation.
