The Effects of Forming and Parameter Mapping on Further Simulation

This paper describes the effects of forming simulation results on crash and durability performance and the impact of the method of transferring results from one simulation to the next. Forming simulation may not always result in a mesh that is ideally suited for static or crash analysis. Tower Automotive has developed software to map forming simulation results from the formed mesh to an entirely different LS-DYNA or NASTRAN mesh of the same part. Simulations of part fabrication represent both hydroforming and mechanical forming. Static simulation is performed in NASTRAN using the work-hardened state as the material input for each element. Other formed parts are subjected to a representative crush load. The effect of transferring results on the same mesh and mapped onto a dissimilar mesh is compared. Results of several crush simulations will be shown, including with forming results, without forming results, and forming results mapped onto a different mesh.