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Technical Paper

An Elastoplastic Damage Coupled Analysis for Crashworthiness of Aluminum Materials

This paper presents a comprehensive damage model capable of predicting crash behavior of aluminum structures under varying applied loading conditions. The damage model has been implemented in a general purpose explicit nonlinear finite element code and crash analysis has been carried out for aluminum tubes. The response obtained from the finite element analysis shows a close agreement with the experimental data. The finite element program containing the proposed generalized damage model can be used to analyze aluminum structures subjected to complex service loading conditions and identify associated failure modes to assess crashworthiness.
Technical Paper

Analysis of Cumulative Damage in a Bumper Due to Multiple Low Speed Impacts

The paper presents a method of analysis based on the theory of damage mechanics to quantify the degree of damage in an engineering structure under load. The method is incorporated into a Ford in-house finite element program called FCRASH that is applied to analyze the cumulative damage in a bumper under multiple low speed impacts. The numerical results calculated at the peak value of the contact force are compared with the test results. The FEA results are used to identify the locations of the hotspot in the bumper system and the predicted location where a potential crack would initiate. The microscopic observations showed damage in the area predicted with the finite element program after the specified number of impacts.
Journal Article

Effect of Temperature Variation on Stresses in Adhesive Joints between Magnesium and Steel

This study considers the thermal stresses in single lap adhesive joints between magnesium and steel. The source of thermal stresses is the large difference in the coefficients of thermal expansion of magnesium and steel. Two different temperature differentials from the ambient conditions (23°C) were considered, namely -30°C and +50°C. Thermal stresses were determined using finite element analysis. In addition to Mg-steel substrate combination, Mg-Mg and steel-steel combinations were also studied. Combined effect of temperature variation and applied load was also explored. It was observed that temperature increase or decrease can cause significant thermal stresses in the adhesive layer and thermal stress distribution in the adhesive layer depends on the substrate combination and the applied load.
Journal Article

Modeling Forming Limit in Low Stress Triaxiality and Predicting Stretching Failure in Draw Simulation by an Improved Ductile Failure Criterion

A ductile failure criterion (DFC), which defines the stretching failure at localized necking (LN) and treats the critical damage as a function of strain path and initial sheet thickness, was proposed in a previous study. In this study, the DFC is revisited to extend the model to the low stress triaxiality domain and demonstrates on modeling forming limit curve (FLC) of TRIP 690. Then, the model is used to predict stretching failure in a finite element method (FEM) simulation on a TRIP 690 steel rectangular cup draw process at room temperature. Comparison shows that the results from this criterion match quite well with experimental observations.
Technical Paper

Parametric Approach for Development of an Automotive Bucket Seat Frame

This paper presents a design and development approach for automotive bucket seat frame using a parametric modeling and a finite element analysis methodology. This approach is expected to help build a lightweight seat structure quickly and efficiently. This approach is general, and it can be applied in designing and developing any mechanical structural component. The design process involves, first parametric modeling of the front bucket seat frame using Pro E. This CAD model was then optimized using optimization software called Optistruct, for two cases of load case and boundary condition. The optimized design was then tested for FMVSS seat requirements using LS-DYNA. The dynamic nature of the design approach helps in changing design parameters during different stages of the design process, until the seat structure satisfies the design criteria and the strength requirements. The construction and testing of this design and the design model are still under progress.