Using Strain Hardening for Advanced Structural Analysis Quality of Vehicle Components
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KIRCHHOFF GRUPPE
Using Strain Hardening for Advanced Structural Analysis Quality of Vehicle Components
Author: Jasmin Brühmann
Kirchhoff Automotive Deutschland GmbH, Attendorn, Germany
(+49-2722-696-0)
KIRCHHOFF GRUPPE
2 [09.11.2011 /Bruehmann]
Agenda
• Introduction
• Problem Defintion
• Analysis/Discussions
Accuracy of HyperForm OneStep
Effects of Strain Hardening
• Conclusions
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Introduction
• Lightweight for crash-relevant parts with new high-strength steels
high levels of strain hardening
lower thickness but same strength
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VW Polo V
Reference: Simulation des Versagens von pressgehärteten Bauteilen aus 22MnB5 + AS80 , Kirchhoff Autmotive GmbH, 2010
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Problem Definition- Forming Simulation
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„Inverse one-step method“
quick and easy but less accurate
needs material and geometry data
HyperForm
OneStep
HyperForm
Radioss Incremental
„Incremental“
more time for model setup
also needs data about tool and process
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Problem Definition- Mapping Results
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HyperMesh HyperCrash
Structural
model
Results forming
simulation
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Analysis Accuracy of HyperForm OneStep (B-Pillar)
• Average deviation of thickness (in comparison to formed part):
Used Software: 0,10 mm (+)
HyperForm Radioss Incremental: 0,10 mm (+/-)
HyperForm OneStep: 0,15 mm (+/-)
• different proportions (force level in structural analysis):
increasing force level caused by plastic strain
decreasing force level caused by thickness reduction
• but finally nearly same results of structural analysis
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Analysis Accuracy of HyperForm OneStep (sub-shell of side member)
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Used Software
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Analysis- Effects of strain-hardening on structural behaviour under loading - B-Pillar HCT580X
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Used Software
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Analysis - Effects of strain-hardening on structural behaviour under loading – Side member LH800
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Analysis - Effects of strain-hardening on structural behaviour under loading – Crash-Box HC300LA / HC380LA
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Used Software
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Conclusions
• Improvement of results depends on part geometry
• Accuracy differences between HyperForm OneStep and Used Incremental Software
x 1/100mm – differences of thickness calculated in forming simulation
a few percent of forcelevel in structure simulation
HyperForm OneStep is suitable for prediction of strain hardening
useful early in the product developement cycle
• Results of HyperForm Radioss Incremental are of equivalent quality
• Results Mapping will be easier
Results Initializer in HyperWorks 11.0
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KIRCHHOFF GRUPPE
Thank you for your attention!
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