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Automotive box section design under torsion: Part 1: Finite element modelling strategy

Abstract Behaviour under torsion is an important performance-related property of automotive box sections. A previous experimental study has identified joining technique, section thickness and section area as the major influencing factors on the torsional behaviour of box hat sections. Using these test results as the basis, a finite element modelling strategy that can simulate the behaviour of adhesively bonded and spot-welded automotive box sections subjected to torsion is presented. The numerical study investigated the effects of material representation, mesh density and layout, and joining technique representation on the stiffness, elastic limit and ultimate strength of the box sections. The final model, calibrated and validated against test results obtained from previous work, was used in an extensive study, presented in the companion paper (Part 2), to further the understanding of the behaviour of torsionally loaded box sections and its implications on weight reduction of automotive structures.