Automotive bodywork, particularly Body-In-White parts, are conventionally manufactured from deep-drawn sheet metal. The production process requires lengthy preparation of expensive moulds and stamps. For safety reasons, each design of parts, such as impact absorbers, so-called crash boxes, must be verified experimentally to meet the crashworthiness requirements obtained from numerical simulations. Unfortunately, some tests fail and the cost, time and effort put into preparing the production tools cannot be used in the final production of the part, increasing the overall R&D costs. In order to make the prototyping of impact-loaded parts faster and more cost-effective, it has been proposed to use one of the Additive Manufacturing (AM) techniques - Laser Powder Bed Fusion process of metal (PBF-LB/M) for fabrication of test series. Such attempt is an attractive alternative due to the elimination of the need for expensive forming dies and reduced lead times. The main challenge is to match the mechanical properties and part behavior under impact loading for AM and conventional sheet metal parts, as well as to create an accurate material model used in FEA simulations. This work will present the results of matching the mechanical properties of one of the advanced high strength steels (AHSS), a low carbon medium manganese steel (LCMMn), as well as impact simulation models with experimental validation of the finished parts. Presented work addresses the importance of material modelling, particularly for materials processed by new manufacturing techniques which, due to specific processing, have a different nominal structure, resulting in non-traditional deformation mechanisms.

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Design, Characterization and FEA Validation of Additively Manufactured Crash-Loaded Vehicle Parts

  • Andrzej Pawlak,
  • Tomasz Kurzynowski

摘要

Automotive bodywork, particularly Body-In-White parts, are conventionally manufactured from deep-drawn sheet metal. The production process requires lengthy preparation of expensive moulds and stamps. For safety reasons, each design of parts, such as impact absorbers, so-called crash boxes, must be verified experimentally to meet the crashworthiness requirements obtained from numerical simulations. Unfortunately, some tests fail and the cost, time and effort put into preparing the production tools cannot be used in the final production of the part, increasing the overall R&D costs. In order to make the prototyping of impact-loaded parts faster and more cost-effective, it has been proposed to use one of the Additive Manufacturing (AM) techniques - Laser Powder Bed Fusion process of metal (PBF-LB/M) for fabrication of test series. Such attempt is an attractive alternative due to the elimination of the need for expensive forming dies and reduced lead times. The main challenge is to match the mechanical properties and part behavior under impact loading for AM and conventional sheet metal parts, as well as to create an accurate material model used in FEA simulations. This work will present the results of matching the mechanical properties of one of the advanced high strength steels (AHSS), a low carbon medium manganese steel (LCMMn), as well as impact simulation models with experimental validation of the finished parts. Presented work addresses the importance of material modelling, particularly for materials processed by new manufacturing techniques which, due to specific processing, have a different nominal structure, resulting in non-traditional deformation mechanisms.