Development of high-efficiency modeling technique for weld-bonded steel joints in vehicle structures - Part I: Static experiments and simulations

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Development of high-efficiency modeling technique for weld-bonded steel joints in vehicle structures - Part I: Static experiments and simulations

Xia, Yong / Zhou, Qing / Wang, P.C. / Johnson, N.L. / Gayden, X.Q. / Fickes, J.D.

To develop an effective modelling technique for weld-bonded structures, fundamental experimental studies, including adherend and adhesive tests, and static tests with spot-welded, adhesive-bonded and weld-bonded coupons, were carried out. These studies reveal the brittle nature of the epoxy-adhesive-bond and the ductile rupture characteristic of the spot-weld pull-out. In the failure process of a weld-bonded structure, the adhesive-bond and the spot-weld fail at different stages and have little coupling effect, but they supplement each other. A modelling strategy was devised and implemented based on the static experimental findings and an assessment of available modelling approaches in a finite-element analysis program. As a result, a combination of the CSW (constrained spot-weld) model and the MISW (mesh-independent spot-weld) model is recommended for modelling the deformation and failure of weld-bonded vehicle structures. An approach for calibrating the failure parameters in the failure criteria is also developed. The recommended modelling method renders satisfactory correlation between simulations and tests at the static coupon test level and acceptable time-step for full-vehicle crash simulations.