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This article covers an application of third-generation advanced high-strength steel (3GAHSS) grades to vehicle lightweight body structure development. Design optimization of a vehicle body structure using a multi-scale material model is discussed. The steps in the design optimization and results are presented. Results show a 30% mass reduction potential over a baseline mid-size sedan body side structure with the use of 3GAHSS.

In this article, the authors illustrate the benefits of axiomatic design (AD) for robust optimization and how to integrate axiomatic design into a total robust design process. Similar to traditional robust design, the purpose of axiomatic design is to improve the probability of a design in meeting its functional targets at early concept generation stage. However, axiomatic design is not a standalone method or tool and it needs to be integrated with other tools to be effective in a total robust development process. A total robust development process includes: system design, parameter design, tolerance design, and tolerance specifications [1]. The authors developed a step-by-step procedure for axiomatic design practices in industrial applications for consistent and efficient deliverables. The authors also integrated axiomatic design with the CAD/CAE/statistical/visualization tools and methods to enhance the efficiency of a total robust development process.

A new solution methodology for optimal spot-weld pattern design is presented. The objective of the optimization is to minimize the total number of welds in a structure while maintaining structural properties above a required level. Two approaches were developed, based on the representation of welds in a finite element model. In the approach ‘without ranking’ welds are represented in a traditional way, as rigid connections. In ‘with ranking’ approach welds are treated as elastic elements subjected to stresses and deformations under given loading conditions. The information on weld stress is utilized in the solution process to reduce the number of design variables and improve the quality of the solution. The applicability of the method to large automotive structures was demonstrated, as well as the capacity for optimization with respect to multiple load sets.

This paper presents development of a multi-scale material model for a 980 MPa grade transformation induced plasticity (TRIP) steel, subject to a two-step quenching and partitioning heat treatment (QP980), based on integrated computational materials engineering principles (ICME Model). The model combines micro-scale material properties defined by the crystal plasticity theory with the macro-scale mechanical properties, such as flow curves under different loading paths. For an initial microstructure the flow curves of each of the constituent phases (ferrite, austenite, martensite) are computed based on the crystal plasticity theory and the crystal orientation distribution function. Phase properties are then used as an input to a state variable model that computes macro-scale flow curves while accounting for hardening caused by austenite transformation into martensite under different straining paths.

The quality of material model input files for finite element analysis (FEA) is a fundamental factor governing the fidelity and accuracy of simulations at a sub-system or a vehicle level, dictating an investment of due diligence in developing and validating the material models. Several material models conventionally employed for FEA typically allow accounting for only uniaxial tensile behavior of the material; however, the models may be required to predict component-level response in a complex loading scenario. Therefore in developing LSDYNA material input files for such models, it becomes critical to validate their performance in alternative loading scenarios. For out-ofplane loading, typically a three or four-point bending load-case is used for validation. Simulating three point bending (TPB), particularly in the quasi-static regime, requires detailed representation of the moving pin impacting the specimen, and sliding of the specimen on the stationary pins.

Accurate material property data in both the elastic and plastic ranges of deformation is essential for accurate material representation in finite element simulations of vehicle systems. Variation of post formed material properties across a part are often of interest in different types of analyses, such as metal forming or fatigue life, for example. Depending on a part's shape it is not always possible to cut standard size tensile test specimens from all areas of interest across the part. Smaller size specimens with curved or tapered gage section may have to be used to promote strain localization and fracture at or near the gage center. This paper presents comparison of quasi-static tensile properties determined using two specimen gage section geometries, straight and tapered. Specifically, the following questions are addressed. How do the engineering strains computed from two-dimensional strain fields obtained by DIC compare to strains measured during standard tensile tests?

Elastomers are widely used in many automotive components such as seals, gaskets etc., for their hyperelastic properties. They can undergo large strain and can return to their original state with no significant deformation making them suitable for energy dissipation applications. Most common testing procedures include uniaxial tension, pure shear, biaxial tension and volumetric compression under quasi-static loading conditions. The results from these tests are used to generate material models for different finite element (FE) solvers, such as LS-DYNA. Commonly used material models for elastomers in LS-DYNA are the Ogden Material Model (MAT77), which uses parameter-based approach and the Simplified Rubber Material Model (MAT181), which uses tabulated input data. Prediction of rate dependent behavior of elastomers is gaining interest as, for example, during a crash simulation the components undergo impact under different strain rates.

This paper presents an overview of a four-year project focused on development of an integrated computational materials engineering (ICME) toolset for third generation advanced high-strength steels (3GAHSS). Following a brief look at ICME as an emerging discipline within the Materials Genome Initiative, technical tasks in the ICME project will be discussed. Specific aims of the individual tasks are multi-scale, microstructure-based material model development using state-of-the-art computational and experimental techniques, forming, toolset assembly, design optimization, integration and technical cost modeling. The integrated approach is initially illustrated using a 980MPa grade transformation induced plasticity (TRIP) steel, subject to a two-step quenching and partitioning (Q&P) heat treatment, as an example.

Thermoplastics find application in many automotive components. Off late, hardware testing is supplemented by analysis using finite element (FE) codes. One of the factors determining the analysis accuracy is the representation of the components with suitable material models. While a uniaxial tensile test on the specimens typically provides engineering stress-strain data, material plasticity models in commercial FE solvers, such as LS-DYNA and ABAQUS, require equivalent plastic strain versus true stress as input. Engineering stress and strain can be converted to the corresponding true stress and true strain using equations based on the constant volume assumption; however, these equations are valid only up to the point of necking.

Cellular foams have found a predominant application in automotive industry for efficient energy absorption so as to meet stringent and continuously improving vehicle crashworthiness and occupant protection criteria. The recent inclusion of pedestrian protection regulations mandate the use of foams of different densities for impact energy absorption at identified impact locations; this has paved the way for significant advancements in foam molding techniques such as dual density and tri-density molding. With increased emphasis on light-weighting, solutions involving the use of polymeric or metallic foams as fillers in hollow structures - foam encapsulated metal structures - are being explored. Another major automotive application of foams is in the seat comfort area, which again involves foams of intricate shapes and sizes. In addition, a few recently developed foams are anisotropic, adding on to the existing complexities.

Hood insulators are widely used in automotive industry to improve noise insulation, pedestrian impact protection and to provide aesthetic appeal. They are attached below the hood panel and are often complex in shape and size. Pedestrian head impacts are highly dynamic events with a compressive strain rate experienced by the insulator exceeding 300/s. The energy generated by the impact is partly absorbed by the hood insulators thus reducing the head injury to the pedestrian. During this process, the insulator experiences multi-axial stress states. The insulators are usually made of soft multi-layered materials, such as polyurethane or fiberglass, and have a thin scrim layer on either side. These materials are foamed to their nominal thickness and are compression molded to take the required shape of the hood. During this process they undergo thickness reduction, thereby increasing their density.