A Strength and Durability Initial Stress Simulation Synthesis Method for the Stamping-Welding-Aging Process of a Sheet Metal Structure

Strength and durability analysis of automotive chassis components often neglects the residual stresses introduced during stamping, welding, and aging processes, which may lead to discrepancies between simulation results and actual performance. To address this issue, this paper proposes an innovative method that integrates the initial residual stresses generated by stamping and welding processes to improve the accuracy of strength and durability analysis. Specifically, the method involves numerically simulating the stamping and welding processes to precisely extract the residual stress field, which is then mapped onto the finite element model. These residual stresses are subsequently consolidated into a format suitable for strength analysis software, enabling a comprehensive consideration of the effects of manufacturing processes. Experimental validation demonstrates that incorporating initial stresses leads to simulation results that closely match the fracture characteristics observed in testing. This novel approach to synthesizing initial stresses provides a more accurate tool for strength and durability assessment in chassis component design, helping to optimize the design process and enhance product performance and reliability.