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1 Modeling Guidelines 1.1 Modeling specification for Body Structure FE models 1.2 Zone definitions 1.2.1 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 zones 1.4.3 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 direction 1.4.14 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 join 1.5.2.5 Coupling nodes in spot and arch welded joints
1.5.2.6 Zone 3 1.6 Modeling of bolted joints 1.6.1 Bolt holes 1.6.2 Modeling of bolted joints 1.6.3 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
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.
Zone 1 Mid rails, Upper rails, Wheel house Cradle, Bumper, Tie bar Dash, Floor, Rocker Apillar, Roof to Bpillar
Zone 2 Bpillar Roof (behind Bpillar) Rear floor (in front of 5bar)
Zone 1 Bpillar, Rocker (impact side) Floor (impact half side) Apillar (impact side) Cpillar (impact side) Roof (impact half side) Rear floor (in front of 5bar) 4.5bar(impact half side) Dash (to tunnel)
Zone 2 Floor (residual) Roof (residual) Rear floor (residual) Dash (residual)
Zone 3 Front structure (in front of Apillar) Rear end structure (luggage compartment)
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: Crash Parameter Value 0.7<J<1.0 J<0.7 5<W<10 Warping 10<W<15 W>15 55<A<90 Minimum interior angle 4-node() 45<A<55 35<A<45 A<35 90<A<125 Maximum interior angle 4-node() Minimum interior angle 3-node() Aspect Ratio 125<A<135 <3% 135<A<145 0% A>145 30<A<60 20<A<30 A<20 5>R>1 5>R>3 R>5 <15% <15% <20% 0% <4% 0% <8% 0% 0% <10% No of 3-node elements <10% ( no 3-node elements
in areas of high stresses)
Static/ Zone Zone Zone Dynamic 1 2 3 0% <3% 1% 0% <3% 0% 0% 0% <15% 8% 0% <10% <3% 0% <10% 0% 0% 10% 0% 0% 0% 0%
Jacobian
0% 0%
<5% 0% 0%
0%
<10% <15% 0% 0% 0% 0%
Table 1.3.1: Element quality requirements for each panel The above criteria should be controlled during preprocessing.
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.
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:
1.3.7.2 Elements
Find and merge (delete) any duplicate elements.
Static/ Dynamic 20
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
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
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
Figure 1.4.13.1: The mesh of panels building up sections shall to the largest possible extent be directed so that it is 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 of such panels are dash, floor and roof.
No elements are allowed to cross the "symmetry" line y=0 (that is nodes shall be positioned on y=0).
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.
Figure 1.5.2.2.1: . The angle between the surface normal and the line between coupled nodes shall be approximately 0, and shall in no case exceed 10
Figure 1.5.2.3.1: Spot welded flange - a coupled node every 40 mm, unless specific spot weld locations were given 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.
Figure 1.5.2.4.1: Arch welded joint and clinched joint - every node in the joint coupled.
1.5.2.6 Zone 3
In zone 3 the modeling of flanges is not necessary the parts shall be connected like arch welded.
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 middle of the hole with the nodes on the perimeter of the hole. The diameter of the outer circle that the quad elements describe is equal to the diameter of the washer in the bolted joint.
Figure 1.6.2.1: Modeling of bolted joints. A rigid connection (Beam Type Spring) is introduced between the centre nodes of the two sides of the joint.
Figure 1.6.3.1: The projected angle between different panels in the bolt joint shall not exceed 5.
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.
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 (8 node) 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.
Grid Name Force Rear Bending Support Front Support Rear Reference Point rocker 1. lateral bending Reference Point rocker 2. lateral bending
Part/Element Name parts driver side Plot elements RBE Elements parts codriver side
Plot element name parts driver side Plot elements RBE Elements parts codriver side
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.
Steel
Young's modulus Shear modulus Density Poisson's ratio E = 204000 G = 78458 = 7.85 x 106 = 0.3 N / mm2 N / mm2 kg / mm3
Aluminum
Young's modulus Shear modulus Density Poisson's ratio E = 70000 G = 26000 = 2.7 x 106 = 0.3 N / mm2 N / mm2 kg / mm3
Glass
Young's modulus Shear modulus Density Poisson's ratio E = 70000 G = 26922 = 2.50 x 106 = 0.3 N / mm2 N / mm2 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
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. Material Rp0.2 1,pl [%] [N/mm2] 174 2,75 209 2,70 293 223 3,40 258 1,05
1 2,pl 2
[N/mm2] 280 300 293 313 323 335 370 345 438
1 QS1010 2 ZSTE-180 3 ZSTE-180 BH 4 ZSTE-220 5 ZSTE-220 BH 5a 6 ZSTE-260 287 3,10 7 ZSTE-300 345 8 ZSTE-340 356 3,80 Table 1.11.3 Material parameters for head processed steel
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.
1.12.3 Diagonals
The deformation of the body opening diagonals is a measure of body stiffness. The main diagonal positions are shown as follows:
-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 Table 1.12.3.1. Named diagonals
- 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)
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.