A Basic Study on Spot Weld Strength Estimation and its Effect on Evaluation of Vehicle Body Strength in a Real World Car to Car Crash Simulation

2002 ◽  
Vol 2002.2 (0) ◽  
pp. 101-102
Keyword(s):  
Real World ◽  
Spot Weld ◽  
Vehicle Body ◽  
Weld Strength ◽  
Basic Study ◽  
Crash Simulation ◽  
Car Crash ◽  
Body Strength

scholarly journals Empirical Study of Car Crash Simulation Analysis within the Development Phase

2019 ◽  
Vol 1 (1) ◽  
pp. 2843-2852 ◽  
Author(s):  
Naouress Fatfouta ◽  
Julie Stal-Le Cardinal ◽  
Christine Royer
Keyword(s):  
Empirical Study ◽  
Qualitative Analysis ◽  
Simulation Analysis ◽  
Development Phase ◽  
Vehicle Model ◽  
Crash Simulation ◽  
Automotive Company ◽  
Car Crash ◽  
Industrial Context ◽  
Current Practices

AbstractCar crash simulation analysis is an important phase within the vehicle development. It intends to analyse the crashworthiness of the vehicle model and examine the level of passive security. However, this activity is not trivial because of the considerable collaboration within the project, the large amount of analysed and exchanged data and a high exigency. Consequently, a solution to assist, ease and reduce the time of the process is desired.To study the current practices followed in the car crash simulation analysis an empirical study has been conducted. This study has been applied within the simulation analysis team, in the development phase, within an automotive company. This paper describes a qualitative analysis of the industrial context and diagnoses the dysfunctions in the current practices. This paper also highlights the current challenges encountered in the car crash simulation analysis.

Determination of Spot Weld Modeling Parameters from Test Data for Finite Element Crash Simulation

2004 ◽  
Author(s):  
Chelliah Madasamy ◽  
Tau Tyan ◽  
Omar Faruque ◽  
Thierry Guimberteau
Keyword(s):  
Finite Element ◽  
Test Data ◽  
Spot Weld ◽  
Crash Simulation

Evaluation of Electrode Degradation and Projection Weld Strength in the Joining of Steel Nuts to Galvanized Advanced High Strength Steel

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
Pablo D. Enrique ◽  
Hashem Al Momani ◽  
Christopher DiGiovanni ◽  
Zhen Jiao ◽  
Kevin R. Chan ◽  
...  
Keyword(s):  
High Strength Steel ◽  
Electrode Materials ◽  
High Strength ◽  
Vehicle Body ◽  
Weld Strength ◽  
Mechanical Degradation ◽  
Class Iii ◽  
Advanced High Strength Steel ◽  
Projection Welding ◽  
Electrode Degradation

Abstract Projection welding of steel weld nuts to advanced high strength steel (AHSS) in automotive applications allows for the reliable mounting of critical components with different thicknesses to the vehicle body. However, the galvanized coatings commonly used on AHSS result in electrode surface degradation during welding. In this study, the electrode degradation and its effect on the mechanical properties of welded steel nuts and AHSS sheets are investigated. Two common electrode materials are tungsten/copper and beryllium-free class III copper—both display the formation of an oxidized alloy surface layer and pitting as weld number increases. Unlike resistance spot welding, where electrodes grow in the contact area diameter as they degrade, projection welding electrodes do not experience this type of mechanical degradation. Instead, increased resistance at the electrode interface with increasing weld number results in higher temperatures at the weld interface and a larger fusion zone size, which is responsible for an observed 30% increase in weld strength over the span of 10,000 welds.

Macro-modeling of spot weld strength and failure

2017 ◽  
Vol 34 (3) ◽  
pp. 941-959 ◽  
Author(s):  
Rim Chtourou ◽  
Nicolas Leconte ◽  
Bassem Zouari ◽  
Fahmi Chaari ◽  
Eric Markiewicz ◽  
...  
Keyword(s):  
Model Updating ◽  
Spot Weld ◽  
Sequential Optimization ◽  
Weld Strength ◽  
Model Parameters ◽  
Content Type ◽  
Pull Out ◽  
Macro Modeling ◽  
Lap Shear ◽  
Optimization Methodology

Purpose This paper aims to propose a macro modeling approach to simulate the mechanical behavior and the failure of spot welded joints in structural crashworthiness computations. Design/methodology/approach A connector element is proposed to simulate the behavior and failure of spot weld joints. An elastic-plastic damageable model is used to describe the non-linear response and rupture. The connector model involves several parameters that have to be defined. Some are directly identified based on mechanical interpretations and experimental tests characteristics. The remaining parameters are identified through a finite element model updating approach using Arcan tests. Resulting from a sensitivity analysis, an original two steps optimization methodology, using the Modes I and II Arcan tests results sequentially, has been implemented to identify the remaining model parameters. Findings The numerical results for Arcan tests in mixed Modes I/II are in a good agreement with the experimental ones. The model is also validated on tensile pull-out, single lap shear and coach-peel tests. Originality/value By comparison with previous published results, the proposed model brings a significant improvement. The main innovative aspects of this work are as follows: the proposed formulation, a reduced number of parameters to optimize, an original sequential optimization methodology based on physical and mechanical analyses and a mesh size independent connector element.

Spot Weld Failure Prediction and Simulation in Crash Analysis

2004 ◽  
Author(s):  
Xiaodong Tang
Keyword(s):  
Major Effect ◽  
Spot Weld ◽  
Vehicle Body ◽  
Design Parameters ◽  
Test Results ◽  
Crash Analysis ◽  
Spring Element ◽  
Weld Failure ◽  
Projection Equations ◽  
Prediction And Simulation

Weld failure/separation in vehicle body structures subjected to impact condition may results in component instability and thus reduced energy absorption. A new finite element method has been developed for modeling the behavior of spot welds in elastic, plastic and separation stages. This method can be used to simulate weld failure in vehicle crash analysis using a failure formulation derived from coupon test results. It is a generalized method and is intended to be applicable to any combination of the weld design parameters such as thickness, materials, coating and impact speed. The method has been validated on the crash tests on straight and S-type rails with a hat section. The CAE prediction based on the modeling procedure correlates well with the test results for all the rail crush cases. The welds are modeled using the beam-type spring element with the newly developed weld damage parameters. The baseline curves for the spring element and the detailed projection equations developed are provided in this paper. The presented method and major effect curves from the testing can also benefit the spot weld design and specification development.

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