Coupled Stamping-Crash process Chains

World-wide surveys on the application of so-called Advanced High Strength Steels have shown that they can improve the energy absorption in crash situations considerably. In Europe and Japan in particular, special multi-phase steels, like DP (Dual Phase) and TRIP (Transformation Induced Plasticity), are increasingly implemented into crash-relevant structures. The most important advantage of these steel grades is the improved formability compared to standard high strength steels, which allows the design of more complex parts with an improved crash performance. The work-hardening behaviour during the plastic deformation compared to standard micro-alloyed steels, for example, is significantly different. This makes it necessary to consider the stamping effects on the material characteristics as well as the gauge reduction of sheet metal parts in crash simulations.

The aim of the project is to improve the crash simulation in these cases significantly by transferring the local forming results.

Differences in FE Models and Codes

The use of a fine mesh with small elements for crash analysis leads to a reduction in the number of time steps, which directly affects the turnaround time of the crash simulation. In the daily business of crash analysis, this is not applicable. On the other hand, the stamping CAE analysts use different FE codes with different meshes, element types and material models for their studies, including adaptive mesh refinement algorithms. These codes do not connect well to the explicit codes used for crash analysis.

Publications

==> Final Report in German / Abschlussbericht zum FAT/AiF-Projekt 171 ZN - 24 MByte PDF

„Untersuchungen zum Einsatz von Wärmebehandlungs-verfahren zur gezielten Beeinflussung des Crashverhaltens von hochfesten Karosseriekomponenten“

Project Partner

Project Contact:

mailto Klaus.Wolf@scai.fhg.de

Research Partners

- Stiftung Institut für Werkstofftechnik Bremen (IWT)

- Institut für Statik und Dynamik der Luft- und Raumfahrtkonstruktionen (ISD)

- Fraunhofer-Institut für Algorithmen und Wissenschaftliches Rechnen (SCAI) Prof.

VDA / FAT Working Group 27

„Finite-Element-Anwendung im Automobilbau“

der Forschungsvereinigung Automobiltechnik e.V. (FAT).

- ThyssenKrupp Steel AG

- DaimlerChrysler AG

- Ford-Werke GmbH

- R. Rieker GmbH

- TECOSIM GmbH

- GNS GmbH

- Faurecia

- Volkswagen AG

- DYNAmore GmbH

- Benteler AG