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Automatic Calibration of Substitute Mechanical Loads Using the Example of Joining Distortion

Automatisierte Ermittlung mechanischer Ersatzlasten am Beispiel des Fügeverzugs
: Ackert, Patrick; Schwarz, Christian

RDO-Journal (2016), No.1, pp.24-29
Journal Article
Fraunhofer IWU ()
Finite Element Method; joining process; distortion; simplified model; parameter identification

Due to the rising possibility of FEM for virtual tolerance prognoses, it is going to use more and more in Car-Body-Production. Besides other it is used to simulate the distortion done by the up to 6000 joining operations (Hu 2001) per car. Because calculating the joining related deformations and integration detailed FE-models for joints in full car models including the effect of joining in the deformation of the car parts would result in prohibitive simulation times simplified model approaches for joins are necessary. The idea behind these simplified approaches is to use mechanical loads to estimate the deformation brought about by joining processes in the FEM. At present, adequate substitute loads for mapping joining distortion is still often derived in a manual calibration process consuming a lot of time and effort.
One approach to automatically calibrating substitute mechanical loads is shown in this publication where the optimizing program optiSLang (Dynardo GmbH) is used for calibration of the mechanical loads for substitute mechanical models. This will not only demonstrate the concept of automatic calibration and how suitable input and output parameters are derived, but, in addition to (Ackert 2015), also the used tools, the generated target function and more detailed the method of the optimization, developed using a real-life joining situation.