Computational modelling of vehicle interior components for impact applications: moulding residual stress

Abstract

This paper presents methods that can be used to connect and transfer the numerical model from structural applications to moulding analysis. Once moulding numerical analysis is performed stress and strain data are exported to be used as initial conditions for the structural analysis. Also a random distribution of the thickness is embedded into the computational model. The material model makes an important contribution to the quality and reliability of the simulation results and each simulation model was evaluated for different material models. Numerical results are compared with experimental data and a score is assigned to the computational models presented in this study. For the first case, the numerical model includes the fixture according to the experiment while a second case is focused on the stand alone model of the cockpit model. By defining a collaborative simulation that uses manufacturing process results, or using codes that can help solving some uncertainties of the model (random thickness) structural analysis becomes more reliable and may provide accurate results that are in good agreement with measured experimental data.

Keywords:

• model conversion
• impact
• moulding
• residual stress
• random thickness
• material model