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Different modeling approaches for efficient distortion calculation of an automotive assembly

Verschiedene Modellierungsansätze für eine effektive Berechnung des Verzugs bei einer KFz.-Baugruppe
: Thater, R.; Perret, W.; Schwenk, C.; Alber, U.; Rethmeier, M.

Vollertsen, F. ; Bremer Institut für Angewandte Strahltechnik:
Thermal forming and welding distortion. Proceedings of the IWOTE 2011 : International Workshop on Thermal Forming and Welding Distortion, Bremen, Germany, April 06 - 07, 2011
Bremen: BIAS, 2011 (Strahltechnik 41)
ISBN: 978-3-933762-35-1
International Workshop on Thermal Forming and Welding Distortion (IWOTE) <3, 2011, Bremen>
Fraunhofer IPK ()
welding simulation; automotive assembly; modeling approach; time-to-solution

In contrast to other simulation fields like forming simulation, welding simulation is still not widely used in industrial environments. A high user expertise, a high time-to-solution and the result accuracy are the most important problems that hinder its extensively application. Different modeling approaches influence these aspects and an analysis of their implementation is of interest especially for the automotive industry as a key user for production simulation. In this study a MIG welded aluminum assembly from the automotive industry is investigated. Experimental and numerical methods are performed. On the experimental side, temperature cycles are obtained with thermocouples and transient distortion fields are measured using a 3D optical analysis system. On the numerical side, threedimensional nonlinear welding simulations are performed using the welding simulation software simufact.welding to obtain the transient distortion field of the investigated industrial assembly. Several modeling approaches are considered and are discussed with respect to the time-to-solution (modeling effort and the calculation time) and the result accuracy. Finally, a FE model with a good result accuracy and a reasonable calculation time for an industrial application is presented.