For reliable full vehicle modelling taking numerous material properties and characteristics into account several boundary conditions need to be full filled. One particular material aspect is the consideration of failure events especially the failure of joint connections. On full vehicle level joint connections can be grouped by three types of connections: 0-D e.g. spot weld, 1-D e.g. weld line and 2-D e.g. bonded face. These types of connections attach in state of the art full vehicle models shell parts that represent the body structure of a vehicle model.
Connection elements must form a suitable link between shell parts of a body structure and one possibility is to model them by using volume elements. Default continuum mechanics solid elements suffer on very small model time steps or on a significant mass increase caused by the Courant criteria. One solution is a special cohesive like connection element which considers only normal and tangential stress in connection direction and is independent from time step restrictions. The presentation will show an overview of the joint requirements on full vehicle level and the cohesive element calibration, validation and application on selected spot welded and bonded physical samples.