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This paper reports the latest development of methodologies for testing and CAE modeling of the automobile mounts. The objective of this study is to provide dynamic mount properties for product evaluation and CAE modeling guideline for crashworthiness simulations. The methodology is divided into component, subsystem and full system levels. The study at the component level is to extract the dynamic parameters of mounts, such as stiffness and damping coefficient, based on the component tests. Furthermore, such parameters are employed to investigate the interaction between mount and connecting structures at the subsystem level. A robust connection mechanism from mount to surrounding structures is also developed during this process. Finally, the results from full vehicle system tests are compared with the CAE simulations to verify the methodology at the component and subsystem levels. A robust component test methodology is the first key element of this study.

Spot weld is the primary joining method to assemble the automotive body structure. In any crash events some separation of spot-welds can be expected. However, if this happens in critical areas of the vehicle it can potentially affect the integrity of the structure. It will be beneficial to identify such issues through CAE simulation before prototypes are built and tested. This paper reports a spot weld modeling methodology to characterize spot weld separation and its application in full vehicle crash simulation. A generalized two-node spring element with 6 DOF at each node is used to model the spot weld. Separation of spot welds is modeled using three alternative rupture criteria defined in terms of peak force, displacement and energy. Component level crash tests are conducted using VIA sled at various impact speeds to determine mean crush load and identify possible separation of welds.