Abstract

Various methods of modeling spot welds with failure criteria are considered for the solver LS-DYNA, a general purpose transient dynamic finite element program. These methods include the failure methodology of the spot weld, the meshing technique of the weld itself, and the resulting dependence on the mesh of the sheet metal attached to the weld. A force-based failure criterion as measured through an assembly of 8 hexahedrons is used to best judge spot weld rupture. This judgment method is calibrated in weld coupon simulations. A script is written in the simulation preprocessor to apply the calibrated failure parameters efficiently in simulations with thousands of spot welds. Finally the method is applied to full vehicle safety simulations where the correlation to actual test results is verified.

References

1. (1) Hallquist, J.: LS-DYNA User’s Keyword User’s Manual, Volume 1, May 2007, Version 971, Livermore Software Technology Corporation (2007)
2. (2) Madasamy, C., Guimberteau, T., Tyan, T., Faruqu, O.: An Investigation of Spot-Welded Steel Connections Using a DOE Approach, SAE Paper, 2003-01-0612 (2003)
3. (3) Malcolm, S., Nutwell, E.: Spotweld Failure Prediction using Solid Element Assemblies, 6th European LS-DYNA Users’ Conference, p 2.47-2.55 (2007)
4. (4) Utsumi, Y., Sato, K., Nomura, N., Suganuma, H., Takada, K., Nii, N., Fujimura, T., Inoue, T., Satonaka, S.: Investigation and Research into CAE Technique for Spot Weld Rupture (Part 1) – Effect of tensile speed on fracture strength of various joints – , JSAE Proceedings May, 2005, no.49-05, JSAE Paper 20055072

Author (organization or company)

• Skye Malcolm（HONDA R&D AMERICAS, INC.）
• Emily Nutwell（HONDA R&D AMERICAS, INC.）

Publication Information

Article of Honda R&D Technical Review Vol.21 No.1 (166 - 174)

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