Study on the Spot-Weld Failure Prediction Model in Auto Crash Simulation
The material failure is the essence of the spot-weld failure. TS Model has been constructed by the base material (BM) zone, the heat-affected zone (HAZ) and the nugget, and takes the failure strain as the unique parameter used for judging material failure
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Abstract The material failure is the essence of the spot-weld failure. TS Model has been constructed by the base material (BM) zone, the heat-affected zone (HAZ) and the nugget, and takes the failure strain as the unique parameter used for judging material failure, so it can be equivalent to the spot-weld failure by simulating the material failure in HAZ. TS Model involves the analysis of five critical problems, which include the spot-weld failure criterion, the reference datum to failure strain, the nugget diameter, the mesh size effect, and the spot-weld material model. TS model takes the material elongation rate as the reference datum of the strain failure. The mesh size in HAZ, which is matched with the material elongation, is determined initially. Meanwhile, the BM consistency assumption is put forward. Finally, the relationship between some factors and the spot-weld failure load has got by TS Model. Because of the simplicity of the failure criterion and the effectiveness of the spot-weld failure prediction, TS Model will have great engineering application value. Keywords TS Model assumption
Failure strain
Mesh size effect
BM consistency
F2012-F01-005 X. Feng (&) Wuhan ShangShan Simulation Technology Co., Ltd, Beijing, China
SAE-China and FISITA (eds.), Proceedings of the FISITA 2012 World Automotive Congress, Lecture Notes in Electrical Engineering 197, DOI: 10.1007/978-3-642-33805-2_4, Ó Springer-Verlag Berlin Heidelberg 2013
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X. Feng
1 Introduction The car crashworthiness is one of the most important vehicle performances. In the crash test, body critical areas often appear the structure failure which is caused by the spot-weld failure. It will directly affect the credibility of the calculation that the full-vehicle crash simulation whether or not can predict the spot-weld failure. The ‘‘spot-weld failure’’ is considered as one of the greatest challenges in the crash simulation [1]. Therefore, it is very significant to develop the suitable spot-weld model for the engineering application and to predict the spot-weld failure in the engineering practice. Therefore, it is very significant to develop the spot-weld model that can be suitable for the engineering application and predictable to the spot-weld failure in the engineering practice.
2 Technical Background All kinds of the spot-weld models have been put forward in a lot of literatures. For example, Omar Faruque et al. [2] use the spring element with two nodes and six degrees to simulate the spot-weld, and the failure criterions are the spot-weld peak force, displacement, and energy and so on. The research of Honda USA [3] shows that using multi solid elements to simulate the spot-weld is more accurate. Toyota makes use of the spot-weld failure model [4] developed by itself to simulate the pull-out failure successfully, and has applied it in the vehicle crash model. The results of numerical simulation agree well with the experimental measurement. It is found that the spot-weld model can be decomposed into some basic construction ele
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