Body-In-White structure of a vehicle mainly consists of hundreds of fabricated sheet metal parts joined with spot welds. Spot welds can rupture during crash testing as the body is deformed and the crash energy is absorbed. Therefore, in order to accurately estimate the crash deformations in FE analysis, it is important to simulate spot weld rupture. This paper describes the development of rapture modeling of spot welds suitable for crash FE analysis in vehicle development process. The authors presented a detailed spot weld rapture model called 'spider web model' in Toyota and confirmed that it closely correlates with actual full vehicle crash test results. Although, the spider web model is accurate, extensive effort is required to construct the model. Also, the spider web model can only simulate the nugget pullout mode of spot weld rapture and it cannot simulate the nugget fracture mode observed in the ultra high strength steels. Many investigations have been conducted on spot weld rapture modeling using mesh free connection which is suitable for vehicle development process. However, these models have not been validated with a full vehicle level test results. A spot weld rapture model using beam element and mesh free connection, which can simulate both nugget pullout and nugget fracture mode of spot weld rapture, has been developed. The developed rupture model is based on spot weld beam element forces and it cannot estimate the plastic strain directly. Therefore, the relationship between plastic strain and rupture function value is investigated. Full vehicle level FE analysis is conducted to confirm the prediction accuracy of developed spot weld rapture model. Results show that spot weld rapture locations and number of raptured spot welds closely correlate with actual crash test results.
Rupture modeling of spot welds suitable for crash FE analysis in vehicle development process
2007
13 Seiten, 22 Bilder, 1 Tabelle, 3 Quellen
Conference paper
English
Rapture Modeling of Spot Welds Suitable for Crash FE Analysis in Vehicle Development Process
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