Adhesive Failure Prediction in Crash Simulations

Hrishikesh S. Rao; Sourabh Tiwari; Sivaprasad Koralla; Debabrata Ghosh; Susanta Dey

doi:10.4271/2019-26-0297

Structural adhesive is a good alternative to provide required strength at joinery of similar and dissimilar materials. Adhesive joinery plays a critical role to maintain structural integrity during vehicle crash scenario. Robust adhesive failure definitions are critical for accurate predictions of structural performance in crash Computer Aided Engineering (CAE) simulations.

In this paper, structural adhesive material characterization challenges like comprehensive In-house testing and CAE correlation aspects are discussed. Considering the crash loading complexity, test plan is devised for identification of strength and failure characteristics at 0°, 45°, 75°, 90°, and Peel loading conditions. Coupon level test samples were prepared with high temperature curing of structural adhesive along with metal panels. Test fixtures were prepared to carryout testing using Instron VHS machine under quasi-static and dynamic loading.

Various material models available in LSDYNA are studied and MAT169 (*MAT_ARUP_ADHESIVE) material model is selected for adhesive material characterization. Finite Element (FE) models inline to the test conditions were prepared. Sensitivity studies carried out to understand the significance of critical parameters in material model and modelling practices. Test and CAE correlation for all the test configurations are established considering quasi-static and dynamic scenarios. Methodology developed for adhesive material modelling and simulations are carried out at BIW and vehicle level using characterized adhesive material model.

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Adhesive Failure Prediction in Crash Simulations 2019-26-0297

SAE MOBILUS