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In this paper, an advanced computational framework is presented for integrated simulation of hydroforming effects and welding assembly operations. The finite element procedures take advantages of existing commercial finite element codes such as ABAQUS by employing a series of user-developed interface modules and a unified material constitutive model formulated with internal state variables that are used to track stress/strain histories induced during forming and welding operations. Its applications in design and welding assembly of hydrofomed components are demonstrated with a series of selected case studies. Based on the detailed finite element simulations described in the above, the following important observations can be made: Weld placements are extremely important in order to mitigate the significant cold work effects in hydroforming.

In this paper, a generalized spot weld model is presented for analyzing various performance attributes of spotwelded automotive structures. The spot weld model employs conventional definitions of beam- or nonlinear spring type elements. The relevant global mechanical properties are presented in the form of six pairs of generalized load-displacement relationships with respect to six degrees of freedom. The required generalized load-displacement relationships can be readily derived with assistance of local finite element welding process model along with limited single-weld coupon testing. As result, the effects of actual weld properties, welding-induced residual stress states, etc. can be incorporated for applications in finite element analysis of complex autobody structures. Its applications in conventional stress analysis for durability prediction, and limit load prediction, and crashworthiness simulation are also discussed with a few selected examples.