Simulation of Automotive Components to Optimize Best Application from Different Grades of Steel Using Finite Element Method (FEM)

Abstract

The automotive industry has been continuously striving to reduce weight in order to improve fuel efficiency and enhance safety. One approach to achieve this is by utilizing high-strength structural components. With each new model, automotive designers make changes to the structural components and material specifications to enhance efficiency and safety. Due to the availability of various high-strength steels with different formability characteristics, it is important to study and identify the most suitable grade of steel for different critical components. To determine the optimal and cost-effective grade of steel for specific applications, FEA-based models offer a cost-effective solution. In this study, a finite element analysis (FEA) model was developed using PAMSTAMP to simulate the forming process of the B-pillar and hood of a car. This model was used to conduct forming simulations of the B-pillar & hood components using six commonly used advanced high-strength steels (AHSS) in the automotive industry: DP590, DP780, DP980, DP1180, and CP780. The developed model predicted and compared potential crack locations, major/minor strains, stress distribution, and thinning profiles for the selected steel grades. The results revealed that DP590 exhibited a higher tendency for wrinkling, while DP980 and DP1180 showed a propensity for cracking at the bend section due to their lower formability. On the other hand, DP780 and CP780 were found to be ideal for the selected B-pillar & hood design. However, CP780 would require a higher blank force compared to DP780. Currently, this model is being utilized for the development of new steel grades and for assessing the suitability of design specifications offline. This reduces the need for physical experiments and enables more efficient advancements in the field.