Modelling self-piercing riveted joint failures in automotive crash structures

This paper describes a new model and method to predict Self-Piercing Riveted (SPR) joint interlock failures in aluminium sheet at crash speeds using explicit finite element simulation. SPR interlock failure is dependent on rivet direction, which is included in the model. A mesh independent approach is adopted for connection model which is capable of industrial application at the full vehicle crash analysis level. The paper provides an overview of the approach to validate connection model; typically by developing detailed physics based models of various joint configurations supported with high speed experimental data, through to model capable of industrial application. The framework to validate connection model for use in crash simulation tools is expected to have broader applicatio

Validating dynamic tensile mechanical properties of sheet steels for automotive crash applications

A thin-wall open channel beam, fabricated from high strength Dual Phase sheet steel, subjected to 3-point bending and constant velocity boundary condition, is investigated to validate material performance for automotive crash applications. Specifically quantitative validation of material tensile data determined from high speed tests and component models, and qualitative validation of materials resistance to fracture. The open channel beam is subjected to quasi-static and increasing loading speed and in all cases, large displacement in which deformation involves formation of a plastic hinge. This paper describes development of test procedure, notably beam specimen design, measurement system and boundary conditions, using both experimental and numerical techniques. The new test procedure, as a compliment to crush testing, will increase confidence in the modeling and application of new advanced higher strength materials in automotive crash structure