The application of magnesium die casting components is widely spread within vehicle applications and has several advantages with regard to other materials. But the use of formed and especially extruded components of magnesium is very limited. On the base of the Finite Element Method (FEM) a new constitutive model for extruded magnesium profiles, useful for crash relevant body components is developed. This constitutive model is implemented into commercial software as a user material law and can be used in the development of vehicle structures. First step is the material characterisation of the magnesium extruded materials. Usually magnesium extrusions show much lower yield in compression than in tension. The negative mechanical properties of extruded profiles can be influenced by alloy modifications as well as modified process technologies, expecially the variation of the extruding parameters to achieve significantly higher extruding velocities. On the base of the material characterisation, the constitutive model is developed and validated. In the last step simulations are performed with the new simulation tool and the results are compared to test results. The developed material model can be used for thin sheets and thin walled extruded materials with asymmetric tension/compression behavior as they could be used in vehicle structural applications made out of extruded magnesium. The model was implemented into commercial crash codes used within the Ford Motor Company. This tool offers the chance to design structural crash relevant vehicle components according to the specific behavior of magnesium. This is one of the main steps for designing stable and cost efficient magnesium parts. Especially for crash relevant structural components the conventional simulation approaches may lead to sub optimal or unstable designs. The new tool helps to shorten development cycles for magnesium extruded parts, fewer prototypes are necessary and 'surprises' during the development phase can be avoided.
Crash simulation on body structural components made out of extruded magnesium
2003
7 Seiten, 11 Bilder, 7 Quellen
Aufsatz (Konferenz)
Englisch
Crash Simulation on Body Structural Components Made out of Extruded Magnesium
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