Robust Design of Front Impact Crash Simulation with FEM by Taking Account of Manufacturing Quality on Spot Weld

Many previous studies on spot weld were focused on how to simulate the rapture behavior with high accuracy at a single simulation under deterministic analysis conditions. In this paper, a stochastic approach is proposed by using Monte Carlo Simulation to evaluate the robustness of front crash performance. First step of this study is takes manufacturing quality into account of simulation. The number and location of rapture spot weld at initial time of crash simulation are treated as random variables of robust analysis. The deviation of accelerations and intrusions due to uncertainty of spot weld in manufacturing process are quantitatively estimated. Final goal of this study is to identify the location number of most important spot welds for controlling manufacturing quality.