Integrated design method for optimal tolerance stack evaluation for top class automotive chassis

Panari, Davide; Renzi, Cristina; Vergnano, Alberto; Bonazzi, Enrico; Leali, Francesco

doi:10.1007/978-3-319-45781-9_101

Cited by 9 publications

(1 citation statement)

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“…Reducing distortions due to the welding process helps increasing the quality of nal product, ful lling tight tolerances on the dimensions and shape of the nal assembly of the chassis ( [32], [33]). A numerical method for simulating distortions on welded chassis is the local/global method ( [24], [29], [32]).…”

Section: More Recent Work ([26]mentioning

confidence: 99%

Design for welding: an application in top class cars chassis

Renzi

Leali²

2022

Preprint

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High quality standards and components downsizing are two main quests of the engineering designers in the nowadays automotive industry. To this aim, lightweight materials as aluminum are used. Moreover, most parts of the automotive chassis made of aluminum are assembled by means of welding techniques. Lightweight materials, such as aluminum, are more and more adopted in chassis design even if the assembly process represents a challenge from a technological point of view, especially due to the distortions caused by the welding process. In case of thin aluminum structures, non-convenient distortions occur due to a combination of effects of fixturing and cooling (after welding) process. The reduction of distortions or almost their prediction is still a very challenging issue, so that no conclusive technique has been found to exclusively fix the problem yet. In this paper, a “design for welding” approach is proposed as an integrated product design and process simulation method, with the aim of predicting the final distortion of an aluminum welded automotive chassis. Thermal-Elastic-Plastic (TEP) finite element analyses (FEA) simulations are capable to provide acceptable results, but require high computational efforts, especially in case of complex geometries as car chassis. To overcome this problem, in this paper, the local-global FEA approach has been adopted with satisfactory results. A top-class car automotive aluminum chassis has been chosen as a case study.

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