Head-neck finite element model of the crash test dummy THOR

Development, calibration and validation of a three-dimensional finite element model of the head-neck sub-assemblies of the THOR 50th percentile male dummy are presented. The model provides, in conjunction with the use of the physical dummy, a computational tool for head-neck injury studies related to motor vehicle, rail, or aircraft crashes. Physical dummy CAD data is used to construct the finite element mesh. Mass and inertia properties of the model are consistent with those of the hardware. The THOR head spring-cable system, designed to produce a neck that gives more biofidelic head trajectories, is properly represented in the model. Several modelling methods are discussed in detail. The deformable components of the model include head skin (vinyl), face foam (Confor foam), face pad (silicone rubber), head springs, neck cables and neck discs (neoprene rubber). The material properties are determined, or calibrated, mainly from system identifications with data from material tests, head and face impact tests on a full dummy and sled tests on stand-alone head-neck sub-assemblies. The model is validated with the remaining sled test data and head-neck pendulum test data. Key simulation results such as head spring forces, motion trajectories, accelerations at head centre of gravity, and neck forces and moments are compared with the corresponding experimental data, and error analyses are conducted for the presented results.