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The need for accurate virtual prototyping prediction is well documented in the literature. For welded body structures one notable shortcoming has been the ability for finite element analysis (FEA) to accurately predict the failure of welded joints due to cyclic loading. A new approach to representing spot-welds for durability evaluation in automotive sheet metal structures is presented here. Excellent correlation with spot-weld failures in actual tests have been observed through this modeling approach. We present a method of representing spot-welds using the finite element method. This method has shown to be able of predicting the behavior of spot-welds prior to the build of any prototypes or testing. Further, for spot-weld failures we present evidence that reveals which radial quadrant of the spot-weld will contain the failure. This method also allows engineers to determine the mechanism of failure. This paper describes in detail the spot-weld modeling method.

The Slam Life Assessment Method (SLAM) is a CAE solution that predicts the durability of automotive closures subject to a repetitive slamming load. Moreover, SLAM is a fully automated program that integrates several software and CAE analyses into a single turnkey solution. SLAM employs the physics of the slam event to succeed where prior analysis methods fail. Standard CAE analyses such as inertia relief, normal modes, and forced loading response cannot capture the physics of the dynamic stress states that occur during a durability slam event. Furthermore, SLAM produces insight into the behavior of the door system that cannot be gained through testing. We have shown that it is possible to predict the performance of a door subject to a slam-closed event with 80-90% reliability. This method has been realized via motivation to solve numerous door panel cracking issues associated with preliminary door designs.