Structural springback analysis of car body closure assemblies using finite element process chain simulations

Abstract

In recent decades, numerical simulation methods have become increasingly important in car body engineering to achieve the high dimensional quality requirements for closure assemblies like bonnets, doors and tailgates. In order to model the entire manufacturing process, latest research works have been focusing on combining the finite element-based simulation models. These complete process chain simulations are able to predict the springback behaviour of the assembly before the physical realization of the tools and processes. The purpose of this study is to introduce a method to use finite element process chain simulations to analyse the structural springback behaviour of car body closure assemblies. Therefore, the numerical process chain simulations are combined with statistical and stochastic tools in order to develop a meta-model, which represents the dimensional accuracy of the investigated assembly. The presented method will then be schematically advanced to be ultimately used in different application areas like robustness and tolerance analyses.