Fatigue Analysis of Welding Seams and Spot Joints in Automotive Structures
Fatigue Analysis of Welding Seams and Spot Joints in Automotive Structures
Fatigue Analysis of Welding Seams and Spot Joints in Automotive Structures
Figure 4: Analytical spot weld model The section forces of the connecting elements only
provide information on the force flow in the spot weld
Analytical expressions for the three components of the itself between both sheets. The section forces however
plane stress state (radial stress, tangential stress and do not give any information on the loading of the welding
shear stress) as a function of all three forces and all spot in the sheet-metal panel itself (see figure 6). In case
three moments are given in [11]. It has been found that of an in-plane loading without any force flow in the spot
measured S-N curves, expressed by structural stresses, weld, such a concept would give zero damage. In reality,
fall within a narrow band for different loading directions however, the welding spot is a potential location of crack
(cross-tension load, tensile shear load) and even for initiation due to the sharp notch between the welded
different sheet thicknesses (0.8-1.2mm). Therefore it is sheets around the spot nugget.
sufficient to use one single S-N curve for the fatigue
assessment of the analytically calculated structural
stresses.
Using the force based approach in conjunction with one The problems described in the previous section are
dimensional finite elements, the following problems solved by a different assessment approach, which
appear: requires a few additional steps to be performed [12]. The
basic idea is not to use the section forces of the
Size and quality of the shell elements connected to the connecting elements but the stresses in a well-defined
one-dimensional beam or rigid elements influence the ring of elements around the joining element. The
section forces as well as the local displacement behavior following steps are required:
(see figure 5). The problem to be solved is how to reach
a constant element size and quality in a complete
structural model.
Step 1: Modification of the FE-Mesh Step 3: Finite Element Analysis
For a raw FE-mesh without any connecting elements, This step generally consists of a linear or geometrically
CAD-Data may directly be put in to generate the spot nonlinear FE analysis with commercial software like
welds at the right location. Otherwise, an arbitrarily NASTRAN. As results, the linear stress distributions
meshed second generation FE-mesh, including should be generated for use in the next steps.
connecting elements, is used. A pre-processor serves to
automatically modify the local FE-mesh around the spot Step 4: Computation of Fatigue
weld. The result is a steady circular element
arrangement around the spot weld in the magnitude of The prediction of the fatigue behavior is based on the
the diameter of the spot weld (see figure 7 for an stress distributions in the element rings. The required
example). local specimen S/N curves for different loading types are
stored in a data base. They were determined by
comparing test and simulation results of specimen (H-
specimen [13], DC-specimen [14]). It was found that
differences in external loading and boundary conditions
have only little influence on the local dynamic strength
value in the assessment element ring. Similarly to the
welding seam fatigue assessment concept, the stress
tensor is transformed to the locally relevant coordinate
system. In the case of welding spots this is the radial,
tangential and shear stress. The kind of loading is
determined by the stress distribution along the ring.
Loading conditions can be pure normal tension or pure
shear tension or generally a mixture of both. The
associated S/N curve is generated by interpolation,
Figure 7: Automatically pre-processed local spot weld considering data from the DC- and H-specimen.
area of a body in white structure
Step 5: Visualization
The new mesh is automatically connected to the rest of
the structure. The constant circular FE-mesh around the For the spot welds, the computed fatigue values in terms
spot weld is the basis for a standardized assessment of damage or endurance safety factors are stored at the
quality of the element stresses. The number of the nodes of the element rings. They can be visualized
elements is increased by 24 per spot weld which can be analogously to stress results together with the fatigue
regarded as a disadvantage of the concept. results in the base material regions using conventional
post-processors. Figure 9 shows an application to a part
Step 2: Correction of Stiffness of a car- body, namely the joint B pillar.
D
Ebeam = C ⋅ t p1 ⋅ rivet
p2
5.3
(8)
where
where
Figure 14: Damage results on spot welds simulated by Force based concepts are not available now and maybe
force based concept (top) and stress based concept it is also not possible to adapt force based concepts for
self piercing rivets, because such methods are too 12. Gumpinger, J.; Hahn, O.; Korte, M; Kudrnac, P;
simple to describe the behavior of self piercing rivets, Singh, S; Unger, B. “Computer Simulated Estimation
which is much more complicated than for spot welds. of the Fatigue Behaviour and Stiffness of Spot Joints
in Automotive Structures", IBEC´97 – International
CONCLUSION Body Engineering Conference, Stuttgart, Germany.
13. Singh, S; Schmid, G; Gao, S. (1991) “ Leichtbau
An overview has been given over some common durch optimierte Fuegetechnik”, lecture and paper
methods and standards for the assessment of welding on the occasion of the DVM Meeting “Bauteil 91” at
seams and spot joints including spot welds and self Berlin, Germany. Proceedings page 239-255.
piercing rivets. It has been shown, how the influence of 14. Hahn, O.; Kurzok, J.R.; Rohde, A.; Thesing, Th.
the mesh quality and the element size can be minimized. (1996): “Konzept zur numerischen Auslegung
For spot welds force based concepts and stress based punktfoermig gefuegter Duennblechstrukturen auf
concepts have been presented. It has been shown, that der Basis experimenteller Versagensanalysen”. LWF
stress based concepts usually deliver better results and
Paderborn, Germany.
can be applied for self piercing rivets too, but the effort
15. H. Dannbauer, C. Gaier, C. Halaszi, “Development of
for the local mesh refinement is very high and error-
a Model for Self-piercing Rivets to Predict Stiffness
prone. For the assessment of some thousand spot welds
in an automotive body in white structure force based and Fatigue Life of Automotive Structures”, IBEC
methods seems to be still superior because of practical 2003, Chiba, Japan, JSAE 20037136, SAE 2003-01-
reasons. Future efforts take aim to improve automatic 2857, pp. 105-110.
node-independent local mesh refinement around spot
joints.
REFERENCES
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