Process development for multi-disciplinary spot weld optimization with CAX-LOCO, LS-OPT and ANSA

The number of connection entities in modern car constructions is growing continuously. From that point of view, the identification of the most suitable structural behaviour of various car body configurations with respect to the number and the arrangement of connections becomes a challenge in automotive development. A standard simulation and optimization process was developed and established in a common project with the Audi AG and DYNAmore GmbH. The simulation model assembly process consists of a car body without any connection entities, a structured data format that describe the connections in detail and an automated process that realizes the connections using ANSA. All of these components are administrated and provided through the AUDI specific simulation data management tool CAx Load Case Composer (LoCo). This software is developed by DYNAmore and provides, among other innovative features, the possibility to parameterize components of the simulation model. With that ability at hand, it becomes possible to introduce parameters for the number of spot welds on a specified line. With the automated assembly process, the simulation engineer becomes able to investigate a number of spot weld configurations with a minimal amount of time and specific process knowledge. Connecting this parameterized assembly process with a structural optimization software like LS-OPT, provides the possibility to set up a systematic investigation of spot weld configurations with respect to any simulation response representing structural performance. The reduction of the total amount of connections under consideration of constraints can be one goal of such an investigation. Also the adjustment of a desired structural stiffness or the control of the deformation behaviour by the connection setup might be possible objectives in that context.