Predictive modelling validates component strength
A
Corus Automotive product story
Edited by the Engineeringtalk editorial team
Sep 11, 2007
Corus worked with Tallent to validate the F2S technique on a suspension lower control arm which uses Corus Tenform XF300 and XF400 HSLA steel grades.
The Corus Forming to Strength (F2S) predictive modelling technique has helped TKA Tallent Chassis validate the strength of sub-assembly components.
All manufacturing processes can change the physical properties of a material.
It is therefore essential that component manufacturers and carmakers understand how steel will perform and behave as it is formed into shape.
Corus has developed a number of modelling techniques that enable customers to include these changes in material properties in crash, fatigue or strength analyses as an integral part of the product development process.
Corus worked with Tallent to validate the F2S technique on a suspension lower control arm which uses Corus Tenform XF300 and XF400 HSLA steel grades.
Conventional finite element strength modelling does not include changes in the steel properties resulting from the forming process.
However, the Corus F2S technique takes the formed thickness and material strength from Pam-Stamp forming analysis and uses this as inputs to Abaqus (finite element software) strength analysis.
Strength tests conducted by Tallent on the lower control arm showed that conventional finite element modelling under-predicts the measured strength by 13%.
When using the Corus F2S technique, the accuracy of the prediction was within 1% of the measured strength.
By using this new computer aided engineering approach, Corus and its customers are able to work together to reduce lead times and therefore costs during the development process.
Rene Kieft, Manager Product and Technology Corus Strip Products said: "Our F2S predictive model is just one of a number of analysis simulation tools, which include Forming to Crash (F2C) and Forming to Fatigue (F2F), that we can provide customers to help them maximise the value of the steel Corus supply".
"Crucially, by using these CAE tools, customers such as Tallent can more quickly and more robustly evaluate the potential benefits of introducing new materials to the component production process during the life span of a vehicle without incurring prohibitive cost and time".
Dr Adam Towse, Analysis Supervisor, TKA Tallent Chassis added: "The ability to introduce new materials is particularly important as there is a growing demand from our OEM customers to use today's modern high-strength and dual-phase steels in order to meet the ongoing need to reduce vehicle weight whilst maintaining performance and strength".
"Corus' predictive modelling techniques allow us to evaluate new materials in order to successfully introduce these modern steel products to the benefit of our customers".
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