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Considering manufacturing effects in automotive structural crashworthiness: A simulation chaining approach

The simulation of the structural crashworthiness of automotive shells is a key function during the product design and development phase. Modern road vehicles require high-complexity product design in order to satisfy the demanding market and the increasing requirements of crash test safety regulations. Product safety issues are highly related to the development of manufacturing processes and material treatment, which will allow for the necessary product structural properties and crash safety. The consideration of the structural properties after the forming process of sheet metal parts and their welding into body assemblies emerge to be essential for a more accurate modelling of the crash behaviour. In this paper, a practical approach for realising the simulation chaining of forming, welding and crash for structural shell assemblies is proposed. The attained structural results of single-sheet metal components are transferred into an integrated model, which enables the side impact simulation of a B-pillar assembly considering the preliminary manufacturing effects.