Browse Publications Technical Papers 2020-01-0182
2020-04-14

Spot Weld Fatigue Correlation Improvement in Automotive Structures using Stress based Approach with Contact Modelling 2020-01-0182

In automotive Body-In-White (BIW) structures, stiffness and the fatigue behavior are greatly influenced by the properties of its joints. Spot welding is one of the most widely used process for joining of sheet metals in BIW. Spot weld fatigue life under Accelerated Durability Test (ADT) is crucial for durability performance of BIW structures. Current experience of BIW validations highlighted significant number of spot weld failures in CAE when compared to actual tests. Hence, lot of iterations in the form of design modifications are required to be carried out to make these CAE failure spots pass which leads to increased design & development time and cost. Current practice uses force-based approach for predicting spot weld fatigue life in CAE under accelerated durability test. In order to improve the spot weld fatigue life correlation, extensive study has been carried out on the approaches for calculating spot weld life, namely force & stress-based approaches. This study highlights the limitations of force-based approach and addresses the advantages of stress-based approach. Standard double cup (DC) spot weld specimen has been used for correlation of test fatigue life with the force based and stress-based approaches. Good correlation improvement has been observed when stress-based approach is used along with contact modelling between panels. Deployment of stress-based approach with contact on full vehicle showed 20% reduction in the failure spot welds in simulation. Overall activity will help in ensuring first time right design and faster design convergence.

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