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Experimental Study on Static and Fatigue Behavior of a Short Glass Fiber Reinforced Polypropylene

FCA US LLC-Mingchao Guo, Congyue Wang, Jian Tao, Ramchandra Bhandarkar
InDepth Engineering Solutions-Johnson Joseph
  • Technical Paper
  • 2020-01-0190
To be published on 2020-04-14 by SAE International in United States
One approach of reducing vehicle weight is using composite materials. Fiber reinforced polypropylene is one of the most popular composite materials. To improve accuracy in prediction of durability performance of structures made of this kind of composite material, static and fatigue properties of a 30% fiber reinforced polypropylene have been physically studied. This paper describes details of test coupon design, fabrication and test setup of both quasi static and fatigue tests. In this study, various fiber orientation (0, 20, 90 degrees & knit line), temperature (-40, 23 and 80 degree C), mean stress (R=-1.0, -0.5, -0.2, 0.1 and 0.4) have been considered and the result of the tests discussed.
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A Robust Cargo Box Structure Development using DFSS Methodology

FCA Engineering India Pvt., Ltd.-Ananta Pankaj
FCA US LLC-Weidong Zhang, Scott Mcguire, Mingchao Guo, Martin Wekerle, Krzysztof Michalowski
  • Technical Paper
  • 2020-01-0601
To be published on 2020-04-14 by SAE International in United States
Cargo box is a key structure in a pickup truck used to hold cargo load. Therefore, a cargo box must be durable and robust under different ballast conditions when subjected to road load inputs. This paper discusses a DFSS approach to resolve a durability concern observed on box bed in its early development phase. Traditional methods and best practices resulted in multiple iterations without an obvious solution. Hence, Design For Six Sigma (DFSS) tools were proposed to find an robust and optimum solution. Key control factors/design parameters were identified, and L18 Orthogonal Array was chosen to optimize design using CAE tools. An optimum design selected was the one with minimum stress level and least stress variation. This design was confirmed to have significant improvement and robustness compared to the initial design. All other load cases are also checked and verified without concern for the selected design.
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Experimental Study on Static and Fatigue Performance of Self-Piercing Riveted Joints and Adhesively Bonded Self-Piercing Riveted Joints Connecting Steel and Aluminum Components

FCA US LLC-Mingchao Guo, Ghassan El-Tawil
  • Technical Paper
  • 2020-01-0177
To be published on 2020-04-14 by SAE International in United States
This paper describes an experimental study on the performance of self-piercing riveted (SPR) joints and adhesively bonded SPR joints connecting steel and aluminum components under both quasi-static and cyclic loading. The joint configurations cover a wide range of material gauges, types and grades. Two and three thickness joints, with and without adhesive are also part of this study. Load versus deflection behavior, load carrying capacity, fatigue life and the failure modes for each type of joint are discussed. This study focuses on the influence of dissimilar material and adhesives to the joint performance. In addition, comparison of load carrying capacity and fatigue strength between SPR and resistance spot welded joints is also discussed.
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CAE Modeling Static and Fatigue Performance of Short Glass Fiber Reinforced Polypropylene Coupons and Components

FCA US LLC-Congyue Wang, Mingchao Guo, Mohan Shanmugam, Ramchandra Bhandarkar
  • Technical Paper
  • 2020-01-1309
To be published on 2020-04-14 by SAE International in United States
Fiber reinforced polypropylene (FRPP) is a typical anisotropic composite and its material properties highly depend on the fiber orientations within the material. To improve accuracy in prediction of durability performance of structures made of this kind of composite material, simulation of manufacturing process is necessary to obtain distribution of fibers and their orientations at every location of the structure. This paper describes a CAE modeling techniques to simulate 1) injection molding process, 2) static and fatigue performance of coupons and 3) static and fatigue performance of components made of 30% FRPP. Details of CAE model setup, analysis procedures and correlation between analysis and test results are presented. In this study, various fiber orientation (0, 20, 90 degrees & knit line), temperature (-40, 23 and 80 degree C) and mean stress (R=-1.0, -0.5, -0.2, 0.1 and 0.4) have been considered. To demonstrate correlation, battery trays made of this FRPP have been tested subjected to block cycle loads, results of which have been discussed.
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A Study on Bolted Joint Finite Element Modeling for Vehicle Level Durability Analysis

FCA US LLC-Weidong Zhang, Mingchao Guo
  • Technical Paper
  • 2020-01-0178
To be published on 2020-04-14 by SAE International in United States
Bolted joints are widely used connections in automotive vehicle structures. However, it has been a challenge to accurately predict static and fatigue behavior of the sheet metal adjacent to the bearing area of bolted joints when linear analysis approach is used. This paper describes an experiment study on static and fatigue behavior of sheet metal adjacent to bearing area of bolted joints which are typically found on vehicles. These joints cover different bolt sizes (M6 to M14), and nut types (hex nut, hex flange nut, round nut, welded nut etc.). Different sheet metal material grades were selected which were, mild steel, high strength steel, dual phase steel and aluminum. The joints were subjected to coach-peel loading condition, because fastened joints have lowest strengths under this condition. 25 different joint combinations were included in this experimental study. For both static and fatigue tests, three samples were tested for each joint type and loading condition combination. Digital Image Correlation (DIC) technique was used to measure strain distributions at critical locations of the samples. Displacement at the loading…
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Failure Modeling of Adhesive Bonded Joints with Cohesive Elements

FCA US LLC-Mingchao Guo
United States Steel Corporation-Guofei Chen
Published 2017-03-28 by SAE International in United States
Advanced high strength steels (AHSS) have been extensively used in the automotive industry for vehicle weight reduction. Although AHSS show better parent metal fatigue performance, the influence of material strength on spot weld fatigue is insignificant. To overcome this drawback, structural adhesive can been used along with spot weld to form weld-bond joints. These joints significantly improve spot weld fatigue performance and provide high joint stiffness enabling down-gauge of AHSS structures. However, modeling the adhesive joints using finite element methods is a challenge due to the nonlinear behavior of the material. In this study, the formulation of cohesive element based on the traction-separation constitutive law was applied to predict the initiation and propagation of the failure mode in the adhesively bonded joints for lap shear and coach peel specimens subjected to quasi-static loadings. The predicted load versus displacement relations correlated well with the test results.
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Fatigue Life Prediction of Friction Stir Linear Welds for Magnesium Alloys

AET Integration Inc.-Chonghua Jiang
FCA US LLC-Mingchao Guo, Yung-Li Lee
Published 2016-04-05 by SAE International in United States
Friction stir linear welding (FSLW) is widely used in joining lightweight materials including aluminum alloys and magnesium alloys. However, fatigue life prediction method for FSLW is not well developed yet for vehicle structure applications. This paper is tried to use two different methods for the prediction of fatigue life of FSLW in vehicle structures. FSLW is represented with 2-D shell elements for the structural stress approach and is represented with TIE contact for the maximum principal stress approach in finite element (FE) models. S-N curves were developed from coupon specimen test results for both the approaches. These S-N curves were used to predict fatigue life of FSLW of a front shock tower structure that was constructed by joining AM60 to AZ31 and AM60 to AM30. The fatigue life prediction results were then correlated with test results of the front shock tower structures.
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Fatigue Life Prediction for Adaptable Insert Welds between Sheet Steel and Cast Magnesium Alloy

AET Integration Inc.-Chonghua Jiang
FCA US LLC-Mingchao Guo, Yung-Li Lee
Published 2016-04-05 by SAE International in United States
Joining technology is a key factor to utilize dissimilar materials in vehicle structures. Adaptable insert weld (AIW) technology is developed to join sheet steel (HSLA350) to cast magnesium alloy (AM60) and is constructed by combining riveting technology and electrical resistance spot welding technology. In this project, the AIW joint technology is applied to construct front shock tower structures composed with HSLA350, AM60, and Al6082 and a method is developed to predict the fatigue life of the AIW joints. Lap-shear and cross-tension specimens were constructed and tested to develop the fatigue parameters (load-life curves) of AIW joint. Two FEA modeling techniques for AIW joints were used to model the specimen geometry. These modeling approaches are area contact method (ACM) and TIE contact method. ACM representation was used to calculate forces and moments for the joints and then calculated the structural stresses while TIE contact representation was used to calculate principal stresses for the joints. The load-life curves were used to construct the appropriate S-N curves based on ACM and TIE contact for different specimen configurations. Then…
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An Experimental Study on Static and Fatigue Strengths of Resistance Spot Welds with Stack-up of Advanced High Strength Steels and Adhesive

FCA US LLC-Mingchao Guo, Ramchandra Bhandarkar, Weidong Zhang
United States Steel Corporation-Guofei Chen, Zhenke Teng
Published 2016-04-05 by SAE International in United States
This paper describes static and fatigue behavior of resistance spot welds with the stack-up of conventional mild and advanced high strength steels, with and without adhesive, based on a set of lap shear and coach peel coupon tests. The coupons were fabricated following specified spot welding and adhesive schedules. The effects of similar and dissimilar steel grade sheet combinations in the joint configuration have been taken into account. Tensile strength of the steels used for the coupons, both as-received and after baked, and cross-section microstructure photographs are included. The spot weld SN relations between this study and the study by Auto/Steel Partnership are compared and discussed.
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A Fatigue Life Prediction Method of Laser Assisted Self-Piercing Rivet Joint for Magnesium Alloys

SAE International Journal of Materials and Manufacturing

AET Integration Inc.-Chonghua Jiang
FCA US LLC-Yung-Li Lee, Mingchao Guo
  • Journal Article
  • 2015-01-0537
Published 2015-04-14 by SAE International in United States
Due to magnesium alloy's poor weldability, other joining techniques such as laser assisted self-piercing rivet (LSPR) are used for joining magnesium alloys. This research investigates the fatigue performance of LSPR for magnesium alloys including AZ31 and AM60. Tensile-shear and coach peel specimens for AZ31 and AM60 were fabricated and tested for understanding joint fatigue performance. A structural stress - life (S-N) method was used to develop the fatigue parameters from load-life test results. In order to validate this approach, test results from multijoint specimens were compared with the predicted fatigue results of these specimens using the structural stress method. The fatigue results predicted using the structural stress method correlate well with the test results.
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