Short answer

Leverage finite element modeling to predict and optimize the performance of systems subjected to extreme impact accelerations, thereby reducing physical testing and accelerating design cycles.

Field: Modelling
Source: Journal of Electronic Packaging (2015)
Method: Simulation and Experimental Validation
Evidence: Strong effect

Finite element modeling (FEM) can reliably simulate the extreme accelerations generated by specialized drop systems, achieving accuracy within 15% of experimental results. This modelling research insight is drawn from a 2015 study published in Journal of Electronic Packaging. Using Simulation and experimental validation, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Leverage finite element modeling to predict and optimize the performance of systems subjected to extreme impact accelerations, thereby reducing physical testing and accelerating design cycles.

Study

ModellingHigh ImpactStrong effect

Finite Element Models Accurately Predict Extreme Impact Accelerations up to 100,000 G

Finite element modeling (FEM) can reliably simulate the extreme accelerations generated by specialized drop systems, achieving accuracy within 15% of experimental results.

Journal of Electronic Packaging · 2015

Key Findings

01FEM can capture peak acceleration for drop towers and DMSAs within 15% of experimental results.
02Design parameters like table mass, spring stiffness, and programmer material significantly affect the drop profile.
03Contact parameters (constraint enforcement, stiffness, damping) influence the accuracy of the FEM simulations.
04Simplified analytic models can provide initial predictions for single impacts and secondary impact dynamics.

Application

Design takeaway

Leverage finite element modeling to predict and optimize the performance of systems subjected to extreme impact accelerations, thereby reducing physical testing and accelerating design cycles.

How to apply

When designing products or systems that must withstand or generate very high impact forces, use FEM to simulate the event and iterate on design parameters before committing to physical prototypes.

Project actions

01When simulating impact events, consider using established software packages that have been validated for similar applications.
02Ensure that material properties and contact definitions in your model are as accurate as possible.
03Always aim to validate your simulation results with at least some physical testing, even if it's a simplified version.

Method & Evidence

AimTo investigate the accuracy of finite element models in simulating the very high accelerations (up to 100,000 G) produced by dual mass shock amplifier (DMSA) drop systems.

MethodSimulation and Experimental Validation

ProcedureA finite element model (FEM) of a commercial drop system utilizing a DMSA was developed and validated against experimental drop tests. Parametric studies were conducted using the FEM to explore the influence of design parameters (table mass, spring stiffness, programmer material) and contact parameters (constraint enforcement, stiffness, damping) on the resulting acceleration profiles. Simplified closed-form analytic models were also developed and compared with test results and FEM predictions.

ContextDesign and testing of high-acceleration impact systems, such as those used for shock testing of electronic components or other sensitive equipment.

Variables

IV["Design parameters (table mass, spring stiffness, programmer material)","Contact parameters (constraint enforcement, stiffness, damping)"]

DV["Peak acceleration","Drop profile"]

CV["Drop height","Initial velocity","Material properties (if not being varied)"]

Strengths & Limitations

Strengths

+Validation of simulation against experimental data provides strong evidence of accuracy.
+Parametric studies allow for a systematic investigation of design influences.

Limitations

The complexity of real-world impacts can be difficult to fully capture in a simulation. Factors like material deformation, temperature changes, and environmental conditions might not be accounted for.

Reliability & validity

The study demonstrates good reliability through consistent simulation results and strong validity through comparison with experimental data, achieving within 15% accuracy for peak acceleration.

Think critically

How might the accuracy of FEM simulations for extreme accelerations be affected by the choice of element type and mesh density?

Design Principles

"Validate simulation models with experimental data to ensure predictive accuracy for critical design parameters."

This capability allows designers and engineers to virtually test and optimize systems designed for high-impact scenarios without the need for extensive and potentially costly physical prototyping. It enables rapid exploration of design variations and material properties to achieve desired acceleration profiles.

What This Means for Your Design

Computer models can accurately predict how hard something will be hit, even in extreme situations, saving time and money on physical tests.

How to use in your project

1.Use this research to justify the use of simulation software in your design project for predicting impact performance.
2.Reference the accuracy figures (e.g., within 15%) to support the reliability of your simulated results.

Add to My Project

Quick Cite

Paragraph starter

Finite element modeling offers a powerful tool for predicting extreme impact accelerations, as demonstrated by research showing accuracy within 15% for specialized drop systems. This allows for virtual prototyping and optimization of designs subjected to high forces, reducing reliance on extensive physical testing and accelerating the design process.

Source

Journal of Electronic Packaging

Simulation of Secondary Contact to Generate Very High Accelerations

journal · 2015

View source

Questions About This Research

What does the research say about finite element models accurately predict extreme impact accelerations up to 100,000 g?: Leverage finite element modeling to predict and optimize the performance of systems subjected to extreme impact accelerations, thereby reducing physical testing and accelerating design cycles. Evidence: Journal of Electronic Packaging (2015).
Why does "Finite Element Models Accurately Predict Extreme Impact Accelerations up to 100,000 G" matter for design?: This capability allows designers and engineers to virtually test and optimize systems designed for high-impact scenarios without the need for extensive and potentially costly physical prototyping. It enables rapid exploration of design variations and material properties to achieve desired acceleration profiles.
How can designers apply this research?: Leverage finite element modeling to predict and optimize the performance of systems subjected to extreme impact accelerations, thereby reducing physical testing and accelerating design cycles.
What were the main findings?: FEM can capture peak acceleration for drop towers and DMSAs within 15% of experimental results.. Design parameters like table mass, spring stiffness, and programmer material significantly affect the drop profile.. Contact parameters (constraint enforcement, stiffness, damping) influence the accuracy of the FEM simulations.. Simplified analytic models can provide initial predictions for single impacts and secondary impact dynamics.
What research method was used?: Simulation and Experimental Validation.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2015 journal from Journal of Electronic Packaging.
What should I do differently in my next project?: When designing products or systems that must withstand or generate very high impact forces, use FEM to simulate the event and iterate on design parameters before committing to physical prototypes.
What are the limitations?: The accuracy of the FEM is dependent on the quality of input parameters and the fidelity of the model to real-world physics. Extrapolation to significantly different architectures or materials may require further experimental validation.