The Effect of Spot Weld Failure on Dynamic （在动态焊点失效的影响）.pdf

The Effect of Spot Weld Failure on Dynamic Vehicle Performance 1 1 1 2 Stijn Donders , Marc Brughmans , Luc Hermans , Nick Tzannetakis 1 LMS International, Interleuvenlaan 68, 3001 Leuven, Belgium; stijn.donders@lms.be, marc.brughmans@lms.be, luc.hermans@lms.be 2 Noesis Solutions, Interleuvenlaan 68, 3001 Leuven, Belgium; nick.tzannetakis@noesis.be ABSTRACT Spot welds are the dominant joining method in the automotive assembly process. As the automated assembly process is not perfect, some spot welds may be absent when the vehicle leaves the assembly line. Furthermore, spot welds are highly susceptible to fatigue, so that a substantial number may fail during the vehicle lifetime. The scope of this paper is twofold. First, the impact of spot weld quality and design on a vehicleís functional performance is reviewed, addressing strength and stiffness, NVH and durability. The overview briefly covers both experimental tests and predictive Finite Element (FE) modeling approaches, explains the complexity of a spot weld design problem and discusses optimization strategies. Second, an industrial robustness study is presented that assesses the effect of spot weld failure on dynamic vehicle characteristics. Damaged models are generated automatically, by breaking a subset of the vehicleís spot welds, using a (weighted)-uniform selection probability. Monte Carlo simulations are then used to assess the scatter on dynamic vehicle characteristics. INTRODUCTION The role of Computer-Aided Engineering (CAE) in the automotive industry is rapidly increasing. Functional performances (NVH, durability, ...) are fine-tuned on t