CAE Virtual Door Slam Test for Plastic Trim Components 2003-01-1209

Visteon has developed a CAE procedure to qualify plastic door trim assemblies under the vehicle door slam Key Life Test (KLT) environments. The CAE Virtual Door Slam Test (VDST) procedure simulates the environment of a whole door structural assembly, as a hinged in-vehicle door slam configuration. It predicts the durability life of a plastic door trim sub-assembly, in terms of the number of slam cycles, based on the simulated stresses and plastic material fatigue damage model, at each critical location. The basic theory, FEA methods and techniques employed by the VDST procedure are briefly described in this paper. Door trim project examples are presented to illustrate the practical applications and their results, as well as the correlation with the physical door slam KLTs. The successful application of CAE virtual KLT has demonstrated that VDST can reduce product development time and cost, by evaluating and improving the durability of plastic door trim components at early design stage, before a prototype is made and physically tested.