Attachment B - Roadsafe LLC

ATTACHMENT B
PANEL COMMENTS ON JUNE 2009 QPR
AND THE EXPERT REVIEW MEETING
NCHRP Project 22-24
Guidelines for Verification and Validation of Crash Simulations used in
Roadside Safety Applications
Panel comments on the June 2009 QPR are included below in a regular font. The research
team‟s responses are shown in an italic font. Also included are some comments received
directly from panel members after the September 9th expert and panel meeting held in
Washington, D.C.
Reviewer #1
I have read Malcolm‟s quarterly report and have the following comments:
1. I had a chance to try out the RSVVP program and feel that it will be a useful
addition the simulation community. The program is fairly straightforward to use
to get results. Having said that, I am a little worried that a lot of effort is going
into making this program, rather than focusing on the ultimate methodology that
is need for V&V. Although there are advantages to having everyone using the
same method, there are also some disadvantages to having a piece of software that
is dedicated to this task.
a. At some point this research project will end and there will no longer be
someone to support this piece of software. As computer operating systems
change over the years, there may be issues with getting the program to
run.
b. By using software to do much of the V&V, you have a “closed system,”
whose inner workings are not necessarily changeable or completely
understood. This is O.K., as long as the software is doing what you want.
However if there is a “bug” or if one wishes to change a piece of the code,
this becomes challenging, especially if there is no designated group who
maintains the software.
c. The final report that is issued with this project needs to include the actual
methodologies and algorithms, so that these are preserved and can be
reviewed and updated as necessary.
We certainly agree that there is a certain risk in using software – things
certainly change in the software and computer world. That said, however,
we also think that a software tool is probably the best way to get people to
use the method since it minimizes the effort they have to invest to get the
analysis done. One advantage to piggy-backing the program on the
MatLab software is that MatLab should take care of most of the long-term
software issues and changing the source code will always be upwardly
compatible with new versions of MatLab. We certainly intend to include
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both a User’s Manual and a Programmer’s Manual in the final report.
We have provided drafts of these documents in earlier QPRs. The
methods (i.e., the bases of the metrics etc.) will be documented such that a
user who wants or needs to do the assessment manual can do so.
2. In the Benchmark cases, I am somewhat troubled by the use of the Geo Metro
model to simulate an impact by a Peugeot, even though they have similar inertial
properties (although I realize there may be a limited supply of crash tests to take
advantage of.) The issues I see are twofold. If you are successful in your
validation, the result suggests that vehicle type (and by extension material
properties and etc.) does not matter, as long as the V&V is successful. This may
in fact be the case, but this issue may be more appropriately addressed in a
separate study. On the other hand, if you are unable to validate the Geo Metro
simulations, is this because the event and simulation are truly different, or is your
evaluation criteria just too stringent? I guess what I am saying is that it seems you
have too many variables. First the test truly is not the same as the simulation
(something that should be evaluated more at a later date), and second, we are still
working to find the correct way to validate test cases.
We certainly appreciate this point. Actually, this is a basic philosophical issue
not only with the V&V procedure but our crash testing procedures as well. The
same can be said for the V&V exercises we have done using the NCAC C2500
pickup truck model – many of the baseline crash tests did not use that particular
vehicle. We have set the acceptance criteria such that we can get passing results
for series of crash test (i.e., crash tests NOT simulations) that are considered
“equivalent” even when the vehicle was not the same. The ROBUST repeated
crash test series did not all use the same make/model/year of vehicles so there is a
certain about of “wiggle room” already in the evaluation. The only way to really
address this problem is to have some organization fund a repeated series of crash
tests with exactly the same vehicle that is available as an FE model. The new
Silverado crash tests and simulations help in this respect but this is certainly a
good point to keep in mind as we go forward.
3. The research group is still evaluating acceptance criteria and I would like to make
the comment that emphasis should be placed on keeping the evaluation criteria as
simple as possible. Results should be easy to understand, not only by the entity
submitting the results, but also the FHWA, and others within the roadside safety
community. For instance the QPR details the ability to use local or global
coordinates and also resultant accelerations. Although this is useful for the team
to understand the best way to analyze the data, ultimately one of these methods
(ideally the simplest) needs to chosen as the standard for all analyses to be run.
We agree. In our past QPRs we have reported on a number of attempts at
acceptance criteria but we have begun reducing them to the most relevant and
easy to understand results. For example, we no longer make any transformations
to the data (e.g., local data is collected in the test and compared to the equivalent
local channel in the simulation). Similarly we started with four weighting
schemes to look at multi-channel data but now we have eliminated all but the one
that we feel gives the best results with the simplest input. We expect retaining the
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Sprague-Geers M and P components but have eliminated the comprehensive (the
C) because it does not provide any additional information. Likewise we expect to
retain the ANOVA metrics but have eliminated the T-statistic because it ends up
being redundant with the other two ANOVA metrics.
Reviewer #2
In addition to inquiries I sent several weeks ago, I have the following comments about the
latest progress report.
1. Acceptance Criteria – I don‟t really like the “peak values” option. Peak values
are very much sampling and filter rate dependent and, I believe, could skew the
results too much. The “inertia properties” would be a pain and might be
meaningless depending upon type of data curve one is inputting.
Neither did we. This has been eliminated.
2. The report seems to concentrate on acceleration traces of the vehicle too much.
There are other data curves that will be used in RSSVP: such as load cell data,
accelerometers attached to hardware devices, strain gauges, string pots, etc. This
should be clear in both the text (reports, manuals, etc) as well as in the RSSVP
menus and results.
True. We have been working most on the full crash test comparisons but the other
part of RSVVP is certainly important as well. We think this will be made more
clear as we continue work on our vehicle and roadside hardware PIRTS since it is
the development of the PIRTS where non-accelerometer data is generally used.
3. Multi-channel seems to be for only the 6 channels from an accelerometer – 3
translation, 3 rotation. I guess I thought it meant I could put in as many or few
curves I wanted from various types of singles and then it would give me a general
overall view of the correlation. For example, I tried to put in just 2 curves (1) acc
of vehicle CG vs time and (2) internal energy vs time, from two separate
simulation cases. In RSVVP it prompted me for the next, or 3rd curve, without the
option to proceed.
No, it is important to remember that this part of RSVVP is specific to comparing
crash test signals so this part of the program assumes that the channels represent
the various channels used in a crash test. The weighting really makes no sense
otherwise. Some improvements have been made, however, to allow users to enter
less than six channels in recognition that some labs do not always use all six
channels. The latest version of RSVVP allows you to skip some of the channels
but in all cases there is assumption that the channels represent accelerometers
and rate gyros in a crash test.
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4. All of the test cases do not have to end up having good correlation. It helps to
have “bad” cases so that things to look for that are bad is often more helpful than
finding things that correlate. But, I understand that people supplying the test
cases do not want their examples to come off looking bad in public.
We agree and, in fact, some of our test cases have not come out that well. The
Geometro comparisons to the ROBUST test, for example, are not as good as we
like. Some of the other test cases where we have assessed the models we have
been able to document changes that we made to the model that helped the scores.
We plan to include all these in the final report.
5. It sounds like you are making every effort to make available the exact dyna decks
and test results being used for the test cases. I support this and think that that is
very important. People will want to run the cases themselves as they learn about
V & V. That helps reinforce what they‟ll read about in the reports and give them
the training they need to perform V & V on their own with confidence.
We agree. Hopefully we can work out an arrangement with the NCAC or FHWA
to post the benchmark cases such that the LSDYNA decks are available to people
in the future to do both validation and verification checks.
6. I sometimes get negative values for the magnitude (M) in Sprauge-Geers MPC.
That‟s confusing to me and I could not find any place what a negative value
means for magnitude.
The negative values in the M metrics just reflect that the simulation magnitude is
tending to under-shoot the true curve. The latest version of RSVVP reports the
absolute value, however, in order to avoid confusion.
Reviewer #3
Task 8A: Roadside Safety Simulation Validation Program (RSVVP)
This section states, “In a future release of the program, this configuration file may be
improved in order to store all of the information necessary to allow a complete
reproduction of a previous computer run”. I strongly encourage the researchers to make
this improvement. The intended use of this program is to support submissions for
acceptance of design changes to safety hardware. Therefore, it is important for the
approving authority to be able to reproduce the computer run.
We agree. This should be implemented in the next version of RSVVP (i.e., version 1.7).
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Task 8D: Roadside Safety Model Best Practices Guide
To date, a formal meeting of the panel for NCHRP 22-24 has not been scheduled for this
summer in San Antonio. Since NCHRP has not offered to fund travel to San Antonio for
the panel members, I do not plan to attend.
I have taken the position that the researcher‟s earlier proposal to develop a more
automated documentation system for LSDYNA models should be tabled until near the
end of this project. However, it has become evident that funding from the States for addon projects will become very tight. An automated documentation system is an interesting
tangent, but it is not necessary for successfully accomplishing the objectives of this
project. Attachment A shows there is barely enough money remaining to complete this
project. Let‟s use that money to successfully complete the research work that‟s already
underway.
We have shelved the automated documentation effort.
Contractual
It is critically important to do the benchmark cases well because this work will give
insights into such questions as weighting factors for the PIRTS etc. This has taken more
time than originally envisioned and this work is not finished. Therefore, it seems
reasonable for the researchers to request a time extension. I recommend that the
researchers prepare a revised bar chart schedule and submit a written request for a time
extension to NCHRP for consideration by the panel.
As mentioned in the body of the QPR, the time extension was in fact granted and the new
end date is in March 2010.
Reviewer #4
I was impressed by the progress your team has made and feel the research is progressing
well. I also thought the inclusion of outside experts was well done. The panel originally
envisioned this step as being a presentation of the research with a review by the experts.
The way you implemented this step, the experts actually used to the software to analyze
test cases, which made their review much more thorough. Some specific comments I
have on the presentations and the research to date follow.
1. I though some more about the filtering that users are able to do in RSVVP and
believe that the procedures should set a minimum value that is acceptable. For
acceleration data, filtering should be done at the frequency of interest, which for
NCHRP 350 would be equivalent to a 10ms moving average. If a higher
frequency is chosen and the model passes the validation, then it can be adequately
used for „350 determination. This means that the model has the necessary
bandwidth to accurately reproduce the phenomena that is being simulated. 50ms
moving averages are not appropriate, as a model that passes at this level of
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filtering may not have sufficient bandwidth to accurately reproduce the
phenomena of interest, which is whether the model can pass a test without small
10ms pulses rising above the 20g limit. True, the validation may show that the
simulation is reproducing the gross vehicular motion, but it is the 10ms moving
average peaks that determine pass or fail in „350. If the simulation is not able to
accurately reproduce these, then the pass/fail criteria can not be accurately
judged.
I suppose we have not been explicit in this point but the reviewer is explaining
what our intent is. It is our intent that the simulation and test data for a crash test
be filtered and compared using the SAE J211 Class 180 filter. This is what
Report 350 specifies so the comparison ought to pass at at least this filter level.
We will make this clearer in the report and forms. RSVVP allows the user to use
a variety of filters and we will probably retain that feature while using a
“default” Class 180 filter. We need to include a place in the V&V report forms
where the filter class is identified.
2. I believe the PIRTs are a good idea and are a necessary part of the validation, as
they document what the model has been validated for. I do not believe that a rigid
set of guidelines should be used as every model (especially hardware models) will
be different and will require a different set of validations/calibrations. This will
make the review process harder for the “decision makers”, as there is no set list of
criteria to check against. Still, an innovative piece of hardware that does not fit
any of the existing categories should not be unfairly penalized because the
designer needs to check “does not apply” to a rigid set of predetermined
guidelines. In this case, of course, the designed would need to devise new PIRT
criteria that are appropriate to the new hardware design.
We agree. We think that the value of the PIRT is that it describes the phenomena
such that a decision maker at least knows what is and is not included in the
model. It is not necessary for the decision maker to know how the phenomenon is
modeled but it at least communicates the modeler’s intentions. We too are
concerned that a rigid framework for the PIRTs will make things difficult.
3. After thinking over the comments in the panel meeting, I agree that failed crash
tests can be used as part of a validation. In fact, failure is necessary at some level
to be able to accurately predict failure. For instance to predict guardrail rupture,
you need to have tested the guardrail (or maybe a guardrail coupon) to failure and
created an appropriate failure model. So a successfully validated model may have
a variety of tests that make up its validation, including some that have failure. At
the same time, a successful test cannot be accurately predicted, without a
validation that includes a successful test. The original goal of this research was to
take a product that had already been certified (i.e. has successful tests), make
some small changes, and then run a simulation to verify that the hardware can still
successfully perform its function. In other words, the design change was small
enough that the change in crash performance is not significant. Taking a test that
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has failed (perhaps catastrophically) and then proving through simulation that it
no longer fails is a significant change in behavior. For instance using the example
discussed during our meeting, a guardrail test that fails due to guardrail rupture
cannot be considered successful if design changes are made in the simulation that
prevent the rupture. True, the rail may no longer rupture, but does the vehicle
now roll? Without a successful test to compare against, we don‟t know.
There are a couple of points in this comment. Certainly, the objective of the
project had to do with minor incremental changes to existing (presumably
accepted) hardware and, as such, there would be no failed crash test. I think
where the issue of failure comes up is that often in a development program there
are tests where there is failure. So, the developer may have some failed test, a
retro-fit and then a new test which did not fail. If all these are available to the
modeler, a validation based on both the failed test and the successful test provides
much more confidence in the model. Unfortunately, we generally have limited
numbers of crash tests to use as baseline times. The point is that we should use as
much of the crash test information as is available to get the most confidence. As
an example, Ray and Plaxico did some development work on the G2 guardrail for
PennDOT. They performed FE simulations to compare against some crash tests
where there was guardrail rupture. They then used the model to explore design
alternatives that would avoid the rupture. Then they performed a crash test to
prove that the FE simulation of the new design was correct.
Reviewer #5
At our last panel meeting, Dr. Ray said that he would accept additional
comments until the end of the month. I have the following additional comments…
I suggest that the name of the computer program be changed to the CURVE program
(CUrve Resemblance and Validation Evaluation). The name CURVE can be pronounced
easily. This will facilitate presentations and discussions. Internet searches for programs
dealing with curves will be able to find it. The present name of the program is essentially
unpronounceable and it can be confused with the name of the RSAP program.
As mentioned in the body of the QPR we have put together a survey monkey survey to get
some input on various alternative names for RSVVP. We have included CURVE as one
of the options.
In order for this computer program to be credible, it must be free of “bugs”. This also
implies that the program must be maintained in the future. Is there any provision in the
contract for future maintence of the program?
We certainly we make our best effort to eliminate any bugs in the program prior to the
end of the contract. There is, however, no provision for maintenance of the program
after the contract is complete.
Reviewer #6
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There was a topic introduced at the 22-24 panel meeting that I meant to comment on
but missed the window. Someone mentioned that due to material processing, items in
guardrails (or vehicles) can be in a pre-stressed state. I remember seeing a talk at the
SAE World Congress in 2001 on this topic, particularly related to getting the stresses
from a stamping process. Then, last week, at my SAE SEAT committee meeting a code
developer mentioned that their software has the capability to model material processes
and use the results as an input into crash simulations.
From the response of others in the room, it sounds like this capability has become fairly
universal in the FE tools. You may already be aware of this, but in case not, I thought I'd
mention it. I'm sure the ls-dyna support can help with this.
It is certainly possible to model pre-stresses and rolling stresses using LSDYNA. The
problem is getting good data. I personally believe, however, that this is a second or third
order effect.
I also remember hearing that you all have a problem similar to mine that different
modelers get different results to the same problem. I got an email today that says the
nuclear power plant community has the same problem, called user effects. I have yet to
hear any solutions, and the problem only becomes obvious when multiple modelers are
asked to run the same scenario which is uncommon in certification. However, I worry
about user effects in certification scenarios, particularly because the effect is not obvious.
I am curious if you have attempted to factor this into your work. If at some point in the
future you evaluate this, I'd like to hear about it.
This is a good point. At this point I don’t think there is anything that we can do. The first
step is to agree on and use a common method for V&V. After we have some experience
in the V&V process and the objective evaluation of models we could do a study where we
ask different analysts to model the same baseline crash and see how they compare.
Also, wanted to let you know that the ASME committee has nearly completed the end to
end example, which includes information about documenting a V&V exercise. Len
Schwer is on the working group. If you contact him, he may be able to send you a draft.
Thanks.
Reviewer #7
Attachment C
Since this presentation will probably be used again in the future, I suggest that the words
“crash tested” be added to the opening sentence in order to make the objective clear. The
following is my suggested wording. “You want to use LSDYNA to develop a new
untested variation or design modification of a crash tested roadside device and submit the
results to a State DOT/FHWA for acceptance.”
Done.
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Revised Interim Report
The revised interim report is in really good shape. I just have a few comments.
Since the first page shows, “revision 1.3 March 2009”, the “DECEMBER 2007” date
could be deleted.
Done.
Page 9, line 10, “researches” should be “researchers”
The foot note at the bottom of page 36 could read: “Please note that Geers and Gear are
two different people.” (At this stage of the development of the interim report, any
misspellings of their names should have been caught and corrected by the authors.)
Done.
Page 83, last sentence. I would suggest the following wording. The SUT model is
intended to be a so-called “bullet model”, i.e. a vehicle model with a reduced number of
elements. This type of model is useful for some types of studies, but it trades off
computational accuracy for increased computational speed. I don‟t want to overemphasize the point, but I think that something more needs to be said about bullet models
from the V&V standpoint.
We have modified the sentence to read “The SUT model is intended to be a so-called
“bullet” model (i.e., a vehicle model with a reduced number of elements) for
computational evaluation of roadside safety hardware.” We respectfully disagree with
the implication of the rest of the sentence. The sentence suggested by the reviewer
implies that bullet models are not accurate or correct. In fact, any model is a “bullet”
model. There is never enough detail to completely define the mechanical response of a
system. What is important is that there be sufficient detail to capture the phenomena of
concern. Whether this can be accomplished with 10,000 elements or a million elements
is a modeling decision that will be tested by the V&V process. Recall that the definition
of validation uses the phrase “for the intended purpose” so the model needs to be
detailed enough to accomplish the objectives of the simulation.
Page 118, eighth line from the bottom. “verification. It should be kept in mind that for
V&V purposes, the curves do not have to be exactly identical. Random experimental
error makes it unlikely that even curves from two identical tests will be the same.
However, for V&V purposes the curves must be functionally equivalent.
Done.
Contractual
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I believe that the 6 month no-cost time extension proposed by the researchers will be
marginal because of the remaining work on the test cases and the best practices
guidelines. I won‟t be surprised if an additional time extension will be required.
We expect to complete the project as presently scoped by the end of March 2010 without
any additional time or funds.
Reviewer #8
My only comment/concern is in Attachment D, Table 1: twice hourglass energy is
compared to total initial energy.
Do you have any references that explain this? From my experience and LS-DYNA
documentation all I‟ve run across is comparison to internal energy at the same specific
time. Also, it is very possible to get lots of hourglass deformations with very low
hourglass energy reported in glstat or matsum. Visual inspection with mesh turned-on is
important. I have no clue how to make that into a measurement, but it is important.
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