Plasticity effects in subsequent simulations of car structures


Kose, Kim and Rietman, Bert (2003) Plasticity effects in subsequent simulations of car structures. In: Complas 2003, VII international conference on computational plasticity, 7-10 April 2003, Barcelona.

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Abstract:In order to further reduce the weight of car components while at the same time
maintaining performance and safe life it is necessary to enhance the simulation process. This
is especially important for chassis parts which have not only a high dynamic load but are also
partly undamped. To reach this goal, the logical step is to couple the successive operations of
forming, assembly and virtual performance testing.
The objective is a complete determination of the mechanical state of the (sub-)assemblies.
It is therefore necessary to consider all forming and joining processes a part has previously
undergone and to consider them in the virtual model. This virtual model is ideally suited for
virtual prototyping (e.g. structural analysis, fatigue, crash) because the complete history of
every part is contained. In contrast to standard models, the changed thickness of sheet metal
parts and residual stresses due to forming and joining as well as the new material state at
every point are known prior to any external loading. This results in a more reliable prediction
of product performance.
Using a relatively simple part it is demonstrated how the performance of chassis parts
changes with the inclusion of plastic forming effects as compared to the exclusion of these
effects. The transfer of the results of the forming process to the comprehensive model is shown
first. Hereafter the model is subjected to static and dynamic external loads. The results are
compared to calculations that use a standard model and show clearly that the inclusion of the
plastic history has a significant influence on the product performance.
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