In the automotive industry, there is an increasing demand for weight reduction as well as safety requirements. These demands have motivated the use of locally optimized components. This study shows how local rigidity of crashrelevant side rails made of multi-phase steels can be improved by local hardening and thus avoiding an increase of the cross section. At the same time simulation process chains were completed and results validated by experiments. A dedicated software tool for the coupling of a wide range of commercially available FEM software products was developed. Codes for metal forming, heat treatment and crash simulations can now be used in one serial workflow. One major aspect here was the transfer of tensor-like values such as stress or strain states. The improvement potential of crash relevant automobile components by local hardening was proven by investigations with generic punched side rails (DP 600 S-Rails). By partial immersing the parts into a 950 deg C hot salt bath a smooth structural change could be achieved. This graded martensite portion causes a higher stiffness in this zone, without generating weak points in the transient area. Parts treated in such a way could absorb the same mechanical energy in the crash test, but proved a reduced deformation way (40%) compared with other standard components. The SCAIMapper software was developed and extended. This tool is able to map results between most of the available FEM codes for stamping, heat treatment, and crash analysis. The SCAIMapper transfers a most data of the final state of a simulation step including the tensor variables to the following model. A new module allows to validate the mapping quality by a fast graphic control. By using this software it was for the first time possible to run a complete simulation chain from stamping through heat treatment to crash analysis. This mapped simulation chain showed a more realistic deformation in the crash simulation.
Multiphysics solutions through code coupling and mapping interfaces
2009
12 Seiten, 9 Bilder, 1 Tabelle, 8 Quellen
Conference paper
Storage medium
English
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