Abstract:
This paper explores the role of virtual prototyping, particularly through finite element analysis (FEA), in improving the efficiency of product development by providing early design insights. It highlights the challenges posed by complex, non-linear materials like foams, and the importance of accurate material properties, especially at high strain rates, which are often not found in standard databases. A case study using the ANSYS/LS-DYNA software simulates a bicycle helmet impact to demonstrate the value of using real-world foam material data in the virtual environment. The model includes a helmet, a human skull, and a rigid telephone pole, all created with CAD tools and meshed using TrueGrid. The simulation applies an initial velocity to the skull and helmet to replicate a collision, with the materials and contact interactions defined using specific FEA models, such as a crushable foam model for the helmet and a viscoelastic model for the skull. The simulation, which required significant computing power, successfully predicts a skull fracture, illustrating the ability of FEA to analyze and predict product performance under extreme conditions. The results of the simulation, based on these FEA techniques, suggest that a helmet redesign is necessary to better dissipate energy and improve wearer safety.
