A numerical approach for efficient and accurate modeling of spot-welding connection in automotive crash analysis

Modeling of spot-welding connection is very important in automotive crash analysis, as spot welding is the main approach to assemble the automobile body from hundreds of press-formed components. Although alternative methods are available for modeling the spot welding, new methods are desirable for better efficiency and accuracy. In this paper, a new approach is proposed for the modeling in an explicit analysis environment. Virtual welding nodes are introduced and constructed from actual nodes of the associated finite element. Given constraints are then imposed on the welding nodes using the Lagrange approach. Good accuracy may be obtained while compatibility with the explicit approach is achieved and numerical stability is unaffected for general mesh layout. The approach is implemented in an explicit code and validated with numerical examples. Copyright © 2007 John Wiley & Sons, Ltd.