This content is not included in your SAE MOBILUS subscription, or you are not logged in.
A Practical Approach to Consider Forming Effects for Full Vehicle Crash Application
ISSN: 0148-7191, e-ISSN: 2688-3627
Published April 20, 2009 by SAE International in United States
Annotation ability available
The forming effects along with strain rate, actual material properties and weld effects have been found to be very critical for accurate prediction of crash responses especially the prediction of local deformation. As a result, crash safety engineers started to consider these factors in crash models to improve the accuracy of CAE prediction and reduce prototype testing. The techniques needed to incorporate forming simulation results, including thickness change, residual stresses and strains, in crash models have been studied extensively and are well known in automotive CAE community. However, a challenge constantly faced by crash safety engineers is the availability of forming simulation results, which are usually supplied by groups conducting forming simulations. The forming simulation results can be obtained by either using incremental codes with actual stamping processes or one-step codes with final product information as a simplified approach. Due to the limitation of resource allocated to crash/safety simulations, incremental simulations are usually conducted only on critical parts such as rail components in a utilized vehicle or frame components in a body-on-frame vehicle that are in the major load paths. In this study, the forming process of a front rail simulated by using incremental and one-step codes are studied and incorporated into crash models as an attempt to understand the difference of their influences. By incorporating incremental and one-step forming results, the responses of crash models are compared with those of physical component tests. The forming process of a second frame is simulated by using a different set of incremental and one one-step codes to provide more data points. The forming results are then carried to full vehicle model for frontal impact analysis. The pulses and deformation modes of the full vehicle impact simulation are compared with those of physical full vehicle test. The comparisons are documented in this paper to understand if it is feasible to use the forming results obtained from one-step forming simulation tools in crash models when forming results simulated by incremental forming tools are not available. It was found that differences of crash results do exist when using the two different methods. However in some cases, the results obtained by using one-step forming tool are acceptable especially when the global responses are the main focus of the crash simulations.
CitationGao, R., Xi, C., Tyan, T., Mahadevan, K. et al., "A Practical Approach to Consider Forming Effects for Full Vehicle Crash Application," SAE Technical Paper 2009-01-0471, 2009, https://doi.org/10.4271/2009-01-0471.
- Kaufman, M. Gaines, D. Kundrick, K. Liu, S.D. “Integrated of Chassis Frame Forming Analysis into Performance Models to More Accurately Evaluate Crashworthiness” SAE 980551
- Gao, R. Pan, L. Tyan, T. Mahadevan, K. et al. “Impact Simulation of Hydro-formed Front End Vehicle Structure” SAE 2006-01-0312
- Qiu, Y.J. Mahadevan, K. Faruque, O. Dombek B.L. “Integration of Hydroforming Analysis of Front-end Structures into Full Vehicle Crash Models” Proceedings of the ASME WAM New Orleans Nov 2002
- Shaw, J. Chen, M. “Metal Forming Characterization and Simulation of Advanced High Strength Steels” SAE 2001-01-1139
- Zeng. D. Liu, S. D. “Specifying Steel Properties and Incorporating Forming Effects in Full Vehicle Impact Simulation” SAE 2002-01-0639
- Zhang, Jianmin Lambrecht, Stephen “Effect of Pre-Deformation on Structural Finite Element Analysis of Mild Steel Parts” SAE 2006-01-0313
- Mahadevan, K. Liang, P. Fekete, J. “Effect of Strain Rate in Full Vehicle Frontal Crash Analysis” SAE 2000-01-0625
- Mahadevan, K. McCoy, R. Faruque, O. “Strain-Rate Characterization of Automotive Steel and the Effect of Strain-Rate in Component Crush Analysis” SAE 982392
- Li, W. Tyan T. Chen, Y. “Data Processing for CAE Material Input with Strain Rate Effects” SAE 2005-01-0359
- Chen, Y. Craig, R. Tyan, T. Cheng, J. “Finite Element Modeling Frame for Body-on-Frame Vehicles, Part 1 - Subsystem Investigation” SAE 2004-01-0688
- Chen, Y. Craig, R. Tyan, T. Cheng, J. “Finite Element Modeling Frame for Body-on-Frame Vehicles, Part: II - Full Vehicle Crash” SAE 2004-01-0689
- Gerdeen, J. Chen, P. “Geometric Mapping Method of Computer Modeling of Steel Metal Forming” Numiform 89
- Batoz J. et al. “An Efficient Algorithm of Estimate the Large Strains in Deep Drawling” Proc. NUMIFORM’89 Rotterdam, Balkema 383 388
- Liu, S. Karima, M. “A One-Step Finite Element Approach for Product Design of Sheet Metal Stamplings” Numerical Methods in Industrial Forming Processes Balkema, Rotterdam 1990
- Sa, C. Zhu, X. “Integrating Metal Forming with Other Performance Analysis Using a Mapping Strategy” SAE 2005-01-0357
- Ghouati, O. Lanzerath, H. “MAPIT a General Data Interface for including Forming History in Product Performance Simulation” Ford Research and Advanced Engineering