Abstract
In order to accurately capture crash behavior during high-speed impact, a large amount of detailed finite element modeling features are needed in the dynamic analysis. An important feature in crash simulation is the amount of detail included in modeling spot weld connections. Traditionally for efficiency, simple node-to-node rigid (MPC) connections for modeling spot weld connections between different components are used in crash models, especially when many components are connected in a fully assembled vehicle crash model. In this work, different levels of complexity in spot weld modeling are examined: (a) simple node-to-node rigid connection, (b) rigid mesh independent spot welds, (c) elastic mesh independent spot welds, and (d) elastic mesh independent spot welds with failure. Mesh-independent spot-weld models define the location of the center point of the spot weld and define the spot weld radius on adjacent surfaces of connected components. A distributed coupling to nodes within the radius specified is automatically created which approximates the behavior of a spot weld of finite size. In order to study the fundamental behavior of different mesh-independent spot weld models, pullout and peal tests between two thin ductile steel plates are performed which isolate different failure modes. Comparisons of reaction force versus displacement curves and internal energy versus displacement for different spot weld models are examined. A case study of a front longitudinal rail for an automobile is presented to illustrate the behavior of the spot-weld models for crash analysis on a realistic and important automotive component which exhibits complex crushing modes with combined axial and bending and designed for strength and energy absorption.
Published Version
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