MEF Modeling Guidelines

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    Modeling guidelines

    1 Modeling Guidelines

    1.1 Modeling specification for Body Structure FE models

    1.2 Zone definitions1.2.1 Zone definitions for Frontal Crash-Model BIW

    1.2.2 Zone definitions for Rear-Side Crash-Model BIW

    1.3 General element quality requirements

    1.3.1 Aspect Ratio

    1.3.2 2D Warpage and 3D Warpage

    1.3.3 Skew

    1.3.4 Taper

    1.3.5 2D Jacobian Ratio and 3D Jacobian Ratio

    1.3.6 Interior angles

    1.3.7 Other modeling checks

    1.3.7.1 Nodes

    1.3.7.2. Elements

    1.3.7.3 Element outlines free angels and faces

    1.3.7.4 2D element normals

    1.4 General modeling rules

    1.4.1 Coordinate system

    1.4.2 Transition between zones1.4.3 Element sides

    1.4.4 Physical properties

    1.4.5 Shell element normals

    1.4.6 Global coordinate system

    1.4.7 SI Units

    1.4.8 Panels

    1.4.9 Holes

    1.4.10 Element edge orientation

    1.4.11 Flange

    1.4.12 Swages

    1.4.13 Element direction1.4.14 Special items for structure model

    1.4.15 Special items for crash model

    1.5 Modeling of flanges and welded joints

    1.5.1 Structure model

    1.5.2 Crash model

    1.5.2.1 Element rows

    1.5.2.2 Angle between surface noramal and line between coupled nodes.

    1.5.2.3 Spot welds

    1.5.2.4 Arch welded joint and clinched join1.5.2.5 Coupling nodes in spot and arch welded joints

    http://f/cax05/PROJECTS/OPEL/modflang/index.htmhttp://f/cax05/PROJECTS/OPEL/modflang/index.htm
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    1.5.2.6 Zone 3

    1.6 Modeling of bolted joints

    1.6.1 Bolt holes

    1.6.2 Modeling of bolted joints1.6.3 Angle between different panels

    1.6.4 Zone 3

    1.7 Modeling of glued joints

    1.7.1 Modeling of glued joints by volume elements

    1.7.2 Modeling of glued joints by springs

    1.8 Modeling of welded hinges

    1.9 Name and numbering, definition of ID's

    1.9.1 Structure model

    1.9.1.1 Grid numbering

    1.9.1.2 Part /Element numbering

    1.9.1.3 Plot element numbering

    1.9.1.4 Physical properties

    1.9.1.5 Model maintenance list

    1.10 Modeling of flanges and welded joints

    1.10.1 Half model

    1.10.2 Full model

    1.10.3 Sub model

    1.10.3.1 Pillar stiffness analysis

    1.10.3.2 Local analysis rear end

    1.10.3.3 Local analysis front end

    1.10.3.4 Roof analysis

    1.10.3.5 Steering analysis

    1.11 Material properties

    1.12 Evaluation methods

    1.12.1 Graphical representation

    1.12.2 Plot elements

    1.12.3 Diagonals

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    1 Modeling Guidelines

    1.1 Modeling specification for body structure FE models

    1.2 Zone definitions

    In the crash-model are some requirements zone dependent, i.e. dependent on the location of the

    panel (elements) in the model. The three zones are defined as follow.

    The structure model (stiffness, durability, dynamic, acoustic analysis) has to be generated with a

    homogeneous mesh. The requirements of element quality on size applies to the complete model.

    The requirements apply to the BIW as well as the hang-on parts.

    1.2.1 Zone definitions for frontal crash-model BIW

    Figure 1.2.1.1: Zone definitions

    Figure 1.2.1.2: Zone definitions

    Zone 1 Zone 2 Zone 3

    Mid rails, Upper rails, Wheel

    houseBpillar Cpillar

    Cradle, Bumper, Tie bar Roof (behind Bpillar) Rear end

    Dash, Floor, Rocker Rear floor (in front of 5bar)

    Apillar, Roof to Bpillar

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    1.2.2 Zone definitions for rear-side crash-model BIW

    Figure 1.2.2.1: Zone definitions

    Figure 1.2.2.2: Zone definitions

    Zone 1 Zone 2 Zone 3

    Bpillar, Rocker (impact Floor (residual) Front structure (in

    side) Roof (residual) front of Apillar)

    Floor (impact half side) Rear floor (residual) Rear end structure

    Apillar (impact side) Dash (residual) (luggage compartment)

    Cpillar (impact side)

    Roof (impact half side)

    Rear floor (in front of 5bar)

    4.5bar(impact half side)

    Dash (to tunnel)

    1.3 General element quality requirements

    Element quality requirements apply to the entire model, but if the special requirements for

    flanges, joints and attachment points, specified in chapter 1.5, are applicable and can not be

    combined with these demands, the special specification for flanges, joints and attachment points

    take precedence.

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    Element quality requirements for each panel is listed below. In combination with the

    requirements for each panel following requirements for the entire model must be fullfilled:

    Parameter Value

    CrashStatic/

    DynamicZone1 Zone2 Zone3

    Jacobian0.7

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    1.3.1 Aspect ratio

    Aspect Ratio between 1 and 5. Aspect Ratio is the ratio of element length to element width (b/a)

    as shown below, where we define length > width for an element.

    Figure 1.3.1.1: Aspect Ratio

    1.3.2 2D Warpage and 3D warpage

    2D Warpage of 5 degree or less, 3D Warpage of 45 degrees or less. A 2D quadrilateral element

    is said to be warped when the 4 corner nodes do not lie in a plane. Warpage is measured by anangle( ) which characterizes the deviation from a plane figure, as shown. A similar test is

    done for the faces of a 3D element.

    1.3.3 Skew

    Skew between 60 and 90 degrees. Skew is measure of the angular deviation of a quadrilateral

    from a rectangular shape. It is defined as the angle ( ) between the lines connecting the

    midpoints of opposite sides of the quadrilateral.

    Figure 1.3.3.1: Skew

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    1.3.4 Taper

    Taper between 0.5 and 1.0. Taper is a measure of the geometric or dimensional deviation of a

    quadrilateral from a rectangle. If we divide a quadrilateral into 4 triangles which have a

    common vertex at the element centroid, then taper is 4 times the area of the smallest triangle (a)divided by the total area.

    Figure 1.3.4.1: Taper

    The following example elements have taper values in the acceptable range:

    Figure 1.3.4.2: Taper=0.5 Figure 1.3.4.3: Taper=0.8

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    1.3.5 2D Jacobian Ratio and 3D Jacobian Ratio

    2D Jacobian Ratio between 1 and 2.5, 3D Jacobian Ratio between 1 and 10.0, and Jacobian

    Zero greater then 0.2. Jacobian Ratio and Jacobian Zero are difficult to show graphically. The

    Jacobian is a measure of the deviation of a given element from an ideally shaped element. TheJacobian is calculated at each vertex of the quadrilateral , and ranges from -1 to +1. The

    Jacobian Ratio is the largest Jacobian of the element divided by smallest Jacobian. The Jacobian

    Zero is the smallest Jacobian of the element. Extreme examples of the kinds of errors detected

    by these tests are shown below.

    Figure 1.3.5.1: Jacobian Ratio - kinds of errors

    1.3.6 Interior Angles

    Interior Angles between 45 and 135 for a quadrilateral element and between 20 and 120 for

    triangular element. These criteria will also detect poorly meshed , as show

    Figure 1.3.6.1: maximum interior angle < 135 Figure 1.3.6.2: minimum interior angle > 20

    Figure 1.3.6.3: maximum interior angle > 45 Figure 1.3.6.4: minimum interior angle < 120

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    1.3.7 Other modeling checks

    1.3.7.1 Nodes

    The model has to be checked for coincident nodes by using a specific tolerance. Keep in mindthat the tolerance used to detect coincident nodes must be chosen carefally. Also, there are some

    instances when merging duplicate nodes is not desirable - for example if a scalar spring is part

    of the model.

    1.3.7.2 Elements

    Find and merge (delete) any duplicate elements.

    1.3.7.3 Element outlines - free edges and faces

    For 2D elements this is a free edge check. Each element that has an edge which is not connected

    to a neighboring element will have that edge highlighted. For example, the mesh on a square

    plate should have free edges at its perimeter but none in the interior. A free edge where the

    material should be continuous is a `crack' in the part and must be repaired. For 3D elements the

    approach is similar using faces of elements.

    1.3.7.4 2D element normals

    Shell element surfaces have a perpendicular or `normal' vector associated with them. Each

    elements normal can point out for or into the body. All of the element normals of a part must

    point in a consistent direction. This is critical when applying a pressure load on a part.

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    1.4 General modeling rulesThese rules apply to the entire model, but if the special rules for flanges, joints and attachment

    points are applicable and can not be combined with these rules, the special rules for flanges,

    joints and attachment points take precedence.

    1.4.1 Coordinate system

    The vehicle coordinate system as given below should be used as the global coordinate system

    for the structure model, for the definition of loads and boundary conditions and also for results

    presentation

    +x horizontal, towards rear of vehicle

    +y horizontal, from centerline to passenger side (LDD)

    +z vertical towards roof

    1.4.2 Transition between zones

    Each panel shall be modeled with shell elements that fulfill the demands specified in Table

    1.3.7.1 and with an element size according to the appropriate zone, see Table 1.4.2.1 The

    transition between these zones has to be smooth.

    ParameterCrash Static/

    DynamicZone 1 Zone 2 Zone 3

    Element size (mm) 10 12 18 25 40 70 20

    Table 1.4.2.1: Element size according to zone

    1.4.3 Element sides

    No elements shall have element sides shorter than 5 times of material thickness, anyway the

    initial time step must not be shorter than 1 microsecond.

    1.4.4 Physical properties

    The elements shall be associated with a material with correct E-module, Poisson's number or G-

    module and density. Elements associated to metallic materials shall also be separated accordingto the yield strength of the material for nonlinear analysis.

    The elements shall be associated with a physical property describing the properties of the panel.

    For structure models the minimum panel thicknesses for crash models the nominal thicknesses

    have to be used.

    Each panel shall have at least one separate physical property id.

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    Figure 1.4.4.1: part definition

    1.4.5 Shell element normals

    The shell element normals shall be consistently defined in the separate panels.

    1.4.6 Global coordinate system

    The model shall be defined in the global coordinate system of the car.

    1.4.7 SI-units

    SI-units shall be used consistently in the model, length in mm.

    1.4.8 Panels

    The panels shall be modeled on the mid surface. If the mid surface is not obtainable from the

    delivered geometry, it is allowed to model on either side of the panel (preferably the tooling

    side).(Crash: anyway the gap between parts in flange areas has to be 0,9mm +/- 0,1mm)

    1.4.9 Holes

    Holes shall be modeled if the diameter are greater than defined in table 1.4.9.1.

    Parameter Zone 1 Zone 2 Zone 3

    D (mm) 10 20 50

    Table 2.4.9.1: Requirements for modeling holes

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    1.4.10 Element edge orientation

    The element edge orientation follows the CAD net lines which are spaced at 100 mm intervals.

    1.4.11 Flange

    The flange on flanged holes and edges shall be modeled if it is wider than 5 mm.

    Figure 1.4.11.1: Modeling of flanged holes with flange smaller than 5mm

    1.4.12 Swages

    Swages shall be modeled according to Figure 1.4.12.1 Figure 1.4.12.5,depending on their

    depth, width and zone relation. If none of the figures are applicable the swage should be

    excluded.

    Figure 1.4.12.1: Modeling of swages with width > 10 mm and depth > 5 mm in zone 1

    Figure 1.4.12.2: Modeling of swages with width < 5 mm and depth > 5 mm in zone 1

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    Figure 1.4.12.3: Modeling of swages with width > 10 mm and depth < 5 mm in zone 1-

    Figure 1.4.12.4: Modeling of swages with width > 10 mm and depth > 5 mm in zone 2

    Figure 1.4.12.5: Modeling of swages with width < 10 mm and depth > 5 mm in zone 2

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    1.4.13 Element direction

    The elements in panels that act as part of a section shall to the largest possible extent be directed

    so that the element sides are parallel or perpendicular to the section, see Fig 2.4.13.1. Examples

    of such panels are rocker, A-pillar and mid rail panels.

    Figure 1.4.13.1: The mesh of panels building up sections shall to the largest possible extent be directed so that itis parallel or perpendicular to the beam section. This means that mesh 1 preferred to mesh 2.

    The elements in panels that do not act as part of sections shall to the largest possible extent be

    directed so that the element sides follow the global coordinate system vectors. Examples ofsuch panels are dash, floor and roof.

    1.4.14 Special items for structure model

    The screen adhesive, hinges and screws/bolts are idealized with CHEXA and CPENTA solid

    elements. Rigid node connections are realized using RBEs. Plot elements (PLOTEL) serve as

    an aid to the visualisation of results in form of displacement curves and deformed/undeformed

    contour comparisons.

    If panels are not modeled on the mid surface according to point 1.4.8 , then the shell element

    normals shall be directed to point from the modeled side to outside of the body. During aproject this orientation has to be constant.

    If major, structurally important differences between parts along center line exists, these parts

    have to be middeled to center line (spare wheel well).

    Generally the left hand side of the body has to be modeled and the simulation of full body

    structure achieved through the use of symmetric or anti-symmetric boundary conditions on the

    axis of symmetry. For special applications and prototype standards the right hand side has to be

    modeled too. These element numbers have an offset of 500 000 to those of the driver side

    equivalents.

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    No elements are allowed to cross the "symmetry" line y=0 (that is nodes shall be positioned on

    y=0).

    1.4.15 Special items for crash model

    The model shall not have any initial penetrations of sheet metals or other parts. Parallel sheetmetals (flanges) or other parts facing each other shall have a gap of 0,9 mm ( 0,1 mm).

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    1.5 Modeling of flanges and welded joints

    1.5.1 Structure model

    The flanges shall be modeled with one element row. and all grids of the inner shape have to beconnected by coincident grids. For specific spot weld analysis special modeling rules will be

    delivered.

    1.5.2 Crash model

    The quality of the mesh in the flanges and weld/clinch joints determines the quality of the

    results and the ease with which modifications to the mesh can be made. Therefore, it is

    extremely important that the flanges and joints are modeled with care. The following points

    must be fulfilled

    1.5.2.1 Element rowsThe flanges shall be modeled with two element rows, see Fig 1.5.2.1.1.

    Figure 1.5.2.1.1: The flanges shall be modeled with two element rows

    1.5.2.2 Angle between surface normal and line between coupled nodes

    The angle between the flange surface normal and the line between two coupled nodes shall be

    approximately 0. It shall not exceed 10, see Fig 1.5.2.2.1. If this demand is not possible to

    achieve with the given geometry, deviation from the geometry or from the location of the

    welding point is allowed whatever reflects better the geometry.

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    Figure 1.5.2.2.1: . The angle between the surface normal and the line between coupled nodes shall beapproximately 0, and shall in no case exceed 10

    1.5.2.3 Spot welds

    If spot welds are included in the geometry, the coupled nodes shall be located at the positions ofthe spot welds. If spot welds are not included in the geometry, a distance between the spot

    welds of approximately 40 mm should be assumed, see Fig 1.5.2.3.1.

    Figure 1.5.2.3.1: Spot welded flange - a coupled node every 40 mm, unless specific spot weld locations weregiven in the geometry. The distance from the inner edge of the flange to the coupled node row shall be greater

    than 7 mm. The picture relates to zone 2.

    The distance from the inner edge of the flange to the middle node row shall not be less than 7

    mm. If this is in conflict with given spot weld geometry, deviation from the spot weld geometry

    is allowed.

    1.5.2.4 Arch welded joint and clinched joint

    Spot clinched joints shall be modeled in the same way as spot welded joints.

    In arch welded joints, every node in the joint shall be coupled, see Fig 1.5.2.4.1.

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    Figure 1.5.2.4.1: Arch welded joint and clinched joint - every node in the joint coupled.

    Clinched joints shall be modeled as arch welded joints.

    1.5.2.5 Coupling of nodes in spot- and arch welded joints

    Beam type springs (RADIOSS type 13) shall be used to achieve the coupling of the nodes in

    spot- and arch welded joints. In general no failure behavior of welding spots is modeled.

    1.5.2.6 Zone 3

    In zone 3 the modeling of flanges is not necessary the parts shall be connected like arch welded.

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    1.6 Modeling of bolted joints

    Where structural components are attached to each other using a bolted joint, they shall be

    modeled according to the requirements in point 1.6.1 1.6.3 Examples of bolted structural

    joints are the crash box mid rail interface and the rear bumper rear longitudinal interface sub frame attachments. Example of a bolted joint that is not considered to be structural, and

    therefore does not have to comply to points 1.6.1 1.6.3 is the fender upper rail interface.

    1.6.1 Bolt holes

    Bolt holes shall be modeled using 6 quad elements to describe the perimeters of the bolt hole

    and washer, see Fig 1.6.1.1. The elements shall be evenly distributed around the hole. If this

    mesh is not possible to achieve with maintained global element length, the elements are allowed

    to be smaller in the vicinity of the bolt hole. No element sides are, however, allowed to be

    smaller than 5mm. If this is not possible to achieve with the given geometry, deviation from the

    geometry is allowed (larger diameter of the hole and/or washer). (Crash: only the perimeter of

    the washer shall be modeled)

    A rigid element shall connect the nodes on the bolt hole perimeter with a node in the middle of

    the hole, see Fig 1.6.1.1.

    The number of elements used to describe the bolt hole and washer shall be the same on all

    panels in the bolt joint.

    Figure 1.6.1.1: Modeling of bolt holes at attachment points and at bolt joints between structural members in the

    BiW. The quad elements are evenly distributed around the hole. A rigid element connects a node in the middleof the hole with the nodes on the perimeter of the hole. The diameter of the outer circle that the quad elementsdescribe is equal to the diameter of the washer in the bolted joint.

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    1.6.2 Modeling of bolted joints

    Rigid elements shall be used to connect the centre nodes of bolt holes of the different panels in

    a bolt joint with each other, see figure 1.6.2.1. (Crash: in general no failure behaviour of bolted

    joints is modeled.

    Figure 1.6.2.1: Modeling of bolted joints. A rigid connection (Beam Type Spring) is introduced between thecentre nodes of the two sides of the joint.

    1.6.3 Angle between different panels

    The projected angle between the elements in different panels in a bolt joint shall not exceed 5,

    see figure 1.6.3.1. (Not for Crash)

    Figure 1.6.3.1: The projected angle between different panels in the bolt joint shall not exceed 5.

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    1.6.4 Zone 3

    In zone 3, none of the requirements 1.6.1 1.6.3 have to be fulfilled. Instead, a node located at

    the centre of the bolt hole shall be connected using RBE2 elements( Rigid Bodies) to

    surrounding nodes in the panel, and to the other bolt hole centre nodes in the bolt joint.

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    1.7 Modeling of glued joints

    1.7.1 Modeling of glued joints by volume elements

    Glue shall, where it exists, be modeled as linear solids. The solid elements shall be of hexa (8node) or penta (6node) type.

    The glue shall have a unique material and physical property id.

    The mesh of the glue shall follow the geometry of the actual glue.

    The boundary nodes of the solid mesh shall be merged with the nodes of the shell meshes,

    between which the glue is situated, see figure 1.7.1.1.

    Figure 1.7.1.1.: Glue modeling

    1.7.2 Modeling of glued joints by springs

    All elements of the glued flanges shall have the same size.

    The elementation of the flanges facing each other shall be identical.

    Two rows of nodes following the geometry of the glueing seam shall be connected with Radioss

    type 13 springs each representing the same volume of glue.

    The springs shall have a function reflecting the force-deflection behavior of the represented

    volume of glue.

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    1.8 Modeling of welded hinges

    Hinges are modeled with CHEXA and CPENTA solid element types. The connecting area is

    modeled about 1/3 finer than the general standard of 25 mm to meet the details and the contact

    definition of the weld seam. Hinge and structure elements are connected by CPENTA solidswhich simulate the weld seam.

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    1.9 Names and Numbering, Definition of IDs

    1.9.1 Structure model

    1.9.1.1 Grid numbering

    Grid Numbering Grid Name

    1998 Force Rear Bending

    1999 Support Front

    2999 Support Rear

    3999 Reference Point rocker 1. lateral bending

    4999 Reference Point rocker 2. lateral bending

    Table 1.9.1.1.1: Grid Numbering

    1.9.1.2 Part/Element numbering

    Part/Element Numbering Part/Element Name

    1000 400000 parts driver side

    401000 450000 Plot elements

    451000 500000 RBE Elements

    501000 900000 parts codriver side

    Table 1.9.1.2.1: Part/Element Numbering

    1.9.1.3 Plot element numbering

    Plot element Numbering Plot element name

    1000 400000 parts driver side401000 450000 Plot elements

    451000 500000 RBE Elements

    501000 900000 parts codriver side

    Table 1.9.1.3.1: Plot element Numbering

    1.9.1.4 Physical Properties

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    If a panel is made of tailored blanks, the panel shall be divided in different physical properties

    according to the different thicknesses and material qualities of the panel.

    1.9.1.5 Model maintenance list

    A list describing the relationship between original CAD data file, physical property names and

    numbers, material names and numbers, and beam section names and numbers shall be

    developed and maintained. The list shall be delivered together with the calculation model both

    in digital form and on paper copies.

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    1.10 FE-model types

    1.10.1 Half model

    Structural half model of driver side with generally 20 mm element size. Element amountbetween 35 000 and 50 000 dependent on body dimension. Asymmetric parts along center line

    (tunnel, spare wheel well, ) have to be moved from local symmetric plane to global symmetric

    plane.

    Figure 1.10.1.1: Half Model

    1.10.2 Full model

    Structural model with asymmetric content. Model size between 70 000 and 100 000 elements

    dependent on body dimensions.

    1.10.3 Sub model

    1.10.3.1 Pillar stiffness analysis

    Half model of driver side including door hinges. Local refinement in area of hinges and door

    lock bracket with about 1/3 of general element size to meet a good grid by grid connection of

    the contact parts for simulating details and the weld seams.

    1.10.3.2 Local Analysis rear end

    Full structure model with asymmetric content. Rear end with boundary conditions in front of

    the B pillar.

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    1.10.3.3 Local analysis front end

    Full structure model with asymmetric content. Front end with boundary conditions behind of

    the B pillar.

    1.10.3.4 Roof analysis

    Half model of driver side. Upper structure with boundary conditions on beltline

    1.10.3.5 Steering analysis

    Full model with asymmetric content. Front end with boundary conditions in front of the B

    pillar.

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    1.11 Material properties

    As Poisson s Ratio defines the relationship between lateral and longitudinal strain only two of

    the values should be input, normally Modulus of Elasticity and Poissons Ratio, thethird being

    derived by the program internally. The values for adhesive are extremely variable and theproperties of the specific material used should be employed. Thus the examples listed below

    apply to one, particular project. In general the model has to be checked for the correct properties

    of specific materials. In case of have standard materials, the specific material data has to be

    used.

    Steel

    Young's modulus E = 204000 N / mm2

    Shear modulus G = 78458 N / mm2

    Density = 7.85 x 106

    kg / mm3

    Poisson's ratio = 0.3

    Aluminum

    Young's modulus E = 70000 N / mm2

    Shear modulus G = 26000 N / mm2

    Density = 2.7 x 106 kg / mm3

    Poisson's ratio = 0.3

    Glass

    Young's modulus E = 70000 N / mm2

    Shear modulus G = 26922 N / mm2

    Density = 2.50 x 106 kg / mm3

    Poisson's ratio = 0.3

    Screen adhesive (Instant Fix)

    Young's modulus E = 5 to 20 N / mm2

    Shear modulus G = 2 to 3 N / mm2

    Density = 1.20 x 106 kg / mm3

    To take into consideration nonlinear material characteristics for QS steel an approximation with

    two straight lines is proposed:

    tension [N/mm2] plastic strain x 10-5

    174.00 0.00

    180.00 200.00

    Table 1.11.1: Material charakteristics for QS steel

    For bake-hardening steel another strain tension curve can be used:

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    tension [N/mm2] plastic strain x 10-5

    250.00 0.00

    256.25 12.00

    262.50 19.00

    268.75 36.00

    275.00 47.00

    281.25 59.00

    287.50 91.00

    293.75 118.00

    297.50 141.00

    300.00 180.00

    305.00 202.50

    Table 1.11.2 Material characteristic for bake-hardening steel

    The following table gives more detailed information for several heat processed steels.

    No. MaterialRp0.2

    [N/mm2]

    1,pl[%]

    1[N/mm2]

    2,pl[%]

    2[N/mm2]

    1 QS1010 174 2,75 250 4,9 280

    2 ZSTE-180 209 2,70 271 5,1 300

    3 ZSTE-180 BH 293 293 293

    4 ZSTE-220 223 3,40 295 4,9 313

    5 ZSTE-220 BH 258 1,05 258 4,3 323

    5a 5,3 335

    6 ZSTE-260 287 3,10 340 5,4 370

    7 ZSTE-300 345 345 345

    8 ZSTE-340 356 3,80 428 5,0 438

    Table 1.11.3 Material parameters for head processed steel

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    1.12 Evaluation methods

    1.12.1 Graphical representation

    Stress plot:

    The stress results derived from Von Mises Theory are represented in a colored graphic. The

    colors are assigned in a way, that blue shows low, and red high stress. If shell elements are

    used, the most unfavorable case of either element top or bottom side should be depicted.

    Deformation plot:

    The deformation plot based on the exploded representation of the structure. The deformations

    are shown by gradual color change from blue to red.

    Animation:

    Animation of the deformed shape allows the assessment of the displayed components. During

    the animation the strain energy distribution or deformation can be colored simultaneously.

    1.12.2 Plot elements

    Plot elements are used to evaluate results automatically at points of interest. These points are,

    for example:

    1. Front longitudinal (rail)

    2. Rocker panel

    3. Rear longitudinal (rail)4. 1st cross member (bar)

    (seat cross member)

    5. 2nd cross member (bar)

    (cross member kick-up)

    6. A-pillar

    7. B-pillar

    8. C-pillar

    9. Tunnel10. Rear wheelhouse

    11. Roof panel

    and are depicted in the sketch below.

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    Figure 1.12.2.1: Plot elements

    1.12.3 Diagonals

    The deformation of the body opening diagonals is a measure of body stiffness. The main

    diagonal positions are shown as follows:

    Figure 1.12.3.1: Diagonals

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    -Front end

    1 Engine hood

    2 Dash panel lower

    3 A-Pillar

    4 Front screen opening

    - Front door opening

    5 Diagonal A

    6 Diagonal B

    7 Diagonal C

    8 Diagonal D

    - B-Pillar

    9 Diagonal

    21 Seperation

    - Rear door opening

    10 Diagonal A

    11 Diagonal B

    19 Diagonal C

    20 Diagonal D

    - Rear end

    12 Wheelhouse/ side panel-belt

    13 Wheelhouse/ C-column up.

    14 Rear screen opening (nb)

    15 Decklid diagonal (nb)

    18 Tail gate opening (hb)

    16 Side screen rear

    22 Side panel deformation (nb)

    Table 1.12.3.1. Named diagonals

    The diagonal deformation is very sensitive to its position. To ensure a good correlation between

    simulation and test result, the exact position of the diagonal has to be checked properly.