Using Strain Hardening for Advanced Structural Analysis Quality of Vehicle Components

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Using Strain Hardening for Advanced Structural Analysis Quality of Vehicle Components

  1. 1. KIRCHHOFF GRUPPE Using Strain Hardening for Advanced Structural Analysis Quality of Vehicle Components Author: Jasmin Brühmann Kirchhoff Automotive Deutschland GmbH, Attendorn, Germany (+49-2722-696-0)
  2. 2. KIRCHHOFF GRUPPE Agenda • Introduction • Problem Defintion • Analysis/Discussions  Accuracy of HyperForm OneStep  Effects of Strain Hardening • Conclusions[09.11.2011 /Bruehmann] 2
  3. 3. KIRCHHOFF GRUPPE Introduction • Lightweight for crash-relevant parts with new high-strength steels  high levels of strain hardening  lower thickness but same strength VW Polo V Reference: Simulation des Versagens von pressgehärteten Bauteilen aus 22MnB5 + AS80 , Kirchhoff Autmotive GmbH, 2010[09.11.2011 /Bruehmann] 3
  4. 4. KIRCHHOFF GRUPPE Problem Definition- Forming Simulation HyperForm HyperForm OneStep Radioss Incremental  „Inverse one-step method“  „Incremental“  quick and easy but less accurate  more time for model setup  needs material and geometry data  also needs data about tool and process[09.11.2011 /Bruehmann] 4
  5. 5. KIRCHHOFF GRUPPE Problem Definition- Mapping Results HyperMesh HyperCrash Structural Results forming model simulation[09.11.2011 /Bruehmann] 5
  6. 6. KIRCHHOFF GRUPPE Analysis Accuracy of HyperForm OneStep (B-Pillar) • Average deviation of thickness (in comparison to formed part):  Used Software: 0,10 mm (+)  HyperForm Radioss Incremental: 0,10 mm (+/-)  HyperForm OneStep: 0,15 mm (+/-) • different proportions (force level in structural analysis):  increasing force level caused by plastic strain  decreasing force level caused by thickness reduction • but finally nearly same results of structural analysis[09.11.2011 /Bruehmann] 6
  7. 7. KIRCHHOFF GRUPPE Analysis Accuracy of HyperForm OneStep (sub-shell of side member) Used Software[09.11.2011 /Bruehmann] 7
  8. 8. KIRCHHOFF GRUPPE Analysis- Effects of strain-hardening on structural behaviour under loading - B-Pillar HCT580X Used Software[09.11.2011 /Bruehmann] 8
  9. 9. KIRCHHOFF GRUPPEAnalysis - Effects of strain-hardening on structuralbehaviour under loading – Side member LH800[09.11.2011 /Bruehmann] 9
  10. 10. KIRCHHOFF GRUPPEAnalysis - Effects of strain-hardening on structuralbehaviour under loading – Crash-Box HC300LA / HC380LA Used Software[09.11.2011 /Bruehmann] 10
  11. 11. KIRCHHOFF GRUPPE Conclusions• Improvement of results depends on part geometry• Accuracy differences between HyperForm OneStep and Used Incremental Software  x 1/100mm – differences of thickness calculated in forming simulation  a few percent of forcelevel in structure simulation HyperForm OneStep is suitable for prediction of strain hardening useful early in the product developement cycle• Results of HyperForm Radioss Incremental are of equivalent quality• Results Mapping will be easier  Results Initializer in HyperWorks 11.0 [09.11.2011 /Bruehmann] 11
  12. 12. KIRCHHOFF GRUPPE Thank you for your attention![09.11.2011 /Bruehmann] 12

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