Research On Mesh Variables Mapping Method In Crash Simulation Based On Stamping Effects And Its Application

Automobile safety, energy conservation and environmental protection are threethemes of automobile industry development nowadays. Improving the precision ofcrash simulation is of great importance for promoting automotive passive safety, andis the major difficulty in this field. In order to improve the precision of crashsimulation analysis, mesh variables mapping method in crash simulation based onstamping effects and its application in thin-walled parts are studied in this paper, somedetails investigated are stated as follows:First of all, this paper aims to establish a new variable mapping technique fortransferring stamping analysis results and material parameters to the crashingsimulation model. This method projects the internal and external crashing nodes ontothe stamping mesh in a different way. Specifically, an inverse iso-parametric mappingalgorithm is adopted inside the stamping mesh; while the extrapolation is used outsidethe stamping mesh. Mesh Variables like the thickness, residual stress and equivalentplastic strain are accurately mapped to the crash model, achieving accuratetransmission of mesh variables between stamping-crash model.Secondly, considering that most of the main energy-absorbing components ofauto-body are thin-walled parts, a square cross-section beam is designed with the highstrength steel DP600, and the stamping effect is adopted into the crash simulationanalysis of the beam with the mesh variables mapping method. Then the effect on thecrashworthiness of specific mesh variable is studied by the variable separation method,including the influence rules of crushing mode of square cross-section, the internalenergy absorption, the collision force and the average collision force of each variable.Finally, In order to research the effect on the vehicle crashworthiness of stampingeffects, with a car as an example, pick several main energy-absorbing thin-walledparts of the car such as the bumper inside and outside panels, energy-absorbing boxand front rail to make crash simulation analysis. The simulation analysis is dividedinto two cases, in one case, only conventional crash simulation analysis is made, andin the other case, the stamping mesh variables is adopted into the energy-absorbingparts`simulation model，that is to say the crash simulation analysis is based on thestamping effects. So that the effect of the stamping effects on the energy-absorbingparts`crashworthiness can be obtained.The research results demonstrate that this method can solve stamping-crash mesh variables transmission problems. It has an important reference value to improve theaccuracy and efficiency of the crash simulation.