Shell and solid modeling for structural body-in-white part

Abstract

Finite-Element Analysis (FEA) is a numerical method that facilitates designers to produce a part with the high degree of reliability. These advantages allow manufacturing engineer to produce a virtual tool prototype. This approach has eliminated the requirement to manufacture the prototype model from soft tool parts and soft tool press die. This research focuses on the numerical experiments for an advanced high-strength steel part in Body-in-White. The patchwork blank sheet of a structural body in white is modeled with three conditions - shell elements without spot welding nuggets, Shell elements with spot welding nuggets and Solid elements. Shell elements are usually the obvious choice in the blank in sheet metal forming simulation primarily due to the rapid and fairly accurate results generated. Solid elements of the other hand require extremely high computation time. The main objective of this study is to critically compare plastic deformation results obtained from three approaches on a B-Pillar part with 1.75mm thickness. The finite-element models are developed from the CAD data of production tool and blank material. The blank material is meshed with quad elements for optimized computing time and results. The input parameters for the simulation models are obtained from the current setup at Press Machine and Production Tool. The analyses of plastic deformation for all three blank material models are compared to the actual part thickness. Percentage of deviation from the actual part geometry will indicate the best approach in producing finite-element models for Hot forming process.