Fatigue Analysis of Welding Seams and Spot Joints in Automotive Structures

H. Dannbauer, C. Gaier, K. Hofwimmer, Magna Steyr, Engineering Center Steyr, St. Valentin, Austria

Overview
hFatigue Analysis of Welding Seams
hCommon European Standards hThe R1MS Concept acc. Radaj hReduction of the Element Size Influence hExample hForce Based Concepts hStress Based Concepts hSelf Piercing Rivets hExamples

hFatigue Analysis of Spot Joints

hConclusion

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EUROCODE 3 and BS 7608: Overview

Assessment of weldings and parent material of steel structures (main application to structural engineering and railway industry) Assessment using nominal stress or hot-spot-stress Classification of the load-time history using rainflow or reservoir counting method Fatigue assessment using linear damage accumulation according Palmgren-Miner in conjunction with one or two slope SN-curves Assessment of normal stress and shear stress S-N curves for particular classified details are given Modifications of the basic S-N curves (sheet thickness influence; weld improvement; annealing)
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EUROCODE 3 and BS 7608: S-N curves for Normal Stress

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Basics of the R1MS Concept

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Calculation of Notch Factors

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Notch Factor Depending on Internal Load

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Analysis Process

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Automatic Stress Correction: Assessment Point Example

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Automatic Stress Correction: Stress for Fine Mesh

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Automatic Stress Correction: Example - Mesh Density

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Automatic Stress Correction: Example - Results

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Example: Rear Axle Subframe

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Possible Definitions of Spot Joints

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Possible Definitions of Spot Joints

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Analytical SPOT Joint Model JSAE

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Influence of Mesh Quality on Beam Forces

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Influence of Beam Inclination on Beam Forces

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Local Mesh Refinement

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Fatigue Analysis of Vehicle Body

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Experimental S/N-Curves

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Comparison Force Based and Stress Based Concept

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Self Piercing Rivet Joint Technology

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Stiffness Model for SP-Rivet

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Underbody Torsion Stiffness Analysis

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Fatigue Analysis of Self Piercing Rivets

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Comparison Test and Fatigue Simulation Results for Rivets

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Conclusions
Force based concepts for spot joint assessment + Efficient method + Pressure cross-tension load can be easily detected (pressure force) - Sensitive to beam position and inclination - How to choose restraint diameter for complex structures ??? Stress based concepts for spot joint assessment + Stiffness can be correctly represented + Reduction of mesh influence + Damage distribution around spot joints can be visualized directly on the FE-structure + Assessment of self piercing rivets - Much effort is necessary for local mesh refinement - Consideration of pressure cross-tension load is difficult

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