NUMERICAL MODELLING AND SIMULATION

LABORATORY REPORT

NAME: ZEYD OKUTAN MATRICOLA: 172754 EXERCISE 3: CAR BODY T-JOINT

1. Abstract The practice concerns the stiffness evaluation of a car body T joint: shear loads, bending moments and torque has to be taken into consideration. The half part of the geometrical model of the T joint is given and the discrete model has to be obtained by using shell elements. The geometrical model representing one half of the structure must be reflected around the symmetry axis with a mirror operation. 2. Discrete Model Set-Up in Hypermesh & Load Conditions The simulation of welded joints represents one of the most important tasks in a car body finite element model definition. Nodes of the elements to be joined can be merged (a single common node for two elements) or joined with mono dimensional elements that simulate the welded point. In this exercise the welded joints will be simulated with rigid elements by using the semi automatic command SPOTWELD. The loads will be applied at the extremity of the upper arm of the joint, while the constraints will lock the degrees of freedom of the other two ends. The former will be applied to a main node called MASTER linked to the nodes of the extremity cross section called SLAVE, the latter directly to the nodes of the extremity cross section.

Figure 1: Car Body T Joint

3. Modeling & Simulation Results In the beginning, we have to import the model which is given as two parts. After importing the model, we can see the half part of T Joint body. Next thing to do is to move the surfaces in order to go on. From Tool menu under Translate we can move one part of 1mm along the zaxes. After this, we have to create a line along the middle lines of flanges to put the spot welds. For this, we can use Geometry menu, under Lines we will find the Offset function the create line. Then we can create the spot welds by using Spotweld function under 1D.

Figure 2: Guide Lines for Spot welds In order to create spot welds, we will use the using geo option with rigid element configuration. Tolerance must be more than 1 mm and spacing will be 20 mm. Then, we can create the mesh with Automesh, and we will select the all surfaces with element size of 5.

Figure 3 Meshed Model ready for Mirror application After creating the meshes, we can have a mirror of model and complete the model. For this, under the Tool menu we will use Reflect command and then we will make the edges certain with Edges command. After that we will create the points of implicated force and the constraints. For this purpose we will use the command Rigids under 1D menu. However we have to create central points of constraints on the sides and one point on the top for the force.

Figure 4 The model is ready for Applied Forces Then we can apply the forces and constraints under the Analysis menu after giving the material properties. After we completed our model with constraints, we will analyze the model with 3 different cases which are implemented in 3 different Loadstep cases. Material properties & Force Conditions t = 1 mm Fx = 1000 N = 0.3 Fy= 1000N E = 210000 MPa Mx = 1000Nm Figure 5 Applied Forces and Moment

1. the force applied on x-axes

2. the force applied on y-axes

3. the force applied on z-axes

4.the moment applied 4

4. Results and Theoretical Calculations From the solved models, we can see the maximum stressed areas of the T-joint and also calculate the stiffness with the maximum displacement and maximum angle movement for the moment applied model. In this way we will do these calculations for different 3 situations of different weld densities given below. K=

& =

Case 1 (Weld Distance 30mm) Displacement K Fx(N) Fz(N) M(Nm)

Case 2 (Weld Distance 20mm) Displacement K

Case 3 (Weld Distance 10mm) Displacement K

0,276mm 30,1mm 0,95

3623 N/mm 33,22 N/mm 1052 N/

0,213mm 28,8mm 0,88

4694 N/mm 34,72 N/mm 1136 N/

0,198mm 26,7mm 0,82

5050 N/mm 37,45 N/mm 1219 N/

Figure 6 - Displacement of the Model with Fx Application

Figure 7 - Displacement of the Model with Fz Application 5

Figure 8 - Displacement of the Model with Moment Application 5. Comparison As the taken results we can briefly see the stiffness is increasing with the density of welding points rises. It is also obvious that the model has a critical displacement when Fz is applied and it moves around 30mm. Analysis were made with 5 mm meshed element sized. We can also see the more critical areas with the shear stress graphs below. Figure 9 Shear Stress Distributions

Shear XY for Fx

Shear XY for Fz