Improving FEM crash simulation accuracy through local thickness estimation based on CAD data

摘要

In this paper, we present a method for estimating local thickness distributionin nite element models, applied to injection molded and cast engineering parts.This method features considerable improved performance compared to two previouslyproposed approaches, and has been validated against thickness measured bydi erent human operators. We also demonstrate that the use of this method forassigning a distribution of local thickness in FEM crash simulations results in amuch more accurate prediction of the real part performance, thus increasing thebene ts of computer simulations in engineering design by enabling zero-prototypingand thus reducing product development costs. The simulation results have beencompared to experimental tests, evidencing the advantage of the proposed method.Thus, the proposed approach to consider local thickness distribution in FEM crashsimulations has high potential on the product development process of complex andhighly demanding injection molded and casted parts and is currently being used byFord Motor Company.