The Assessment of a Combined Methodology for Spot Weld Failure Modeling 2004-01-0690

Joint failure, e.g. resistance spot weld (RSW) joint failure, has been identified as one of the key failure modes when vehicle crash occurs. Currently, a beam element or a rigid link is commonly used to represent a RSW in a full vehicle analysis. Several failure criteria have been implemented in the math-based tools to model the spot weld failure, namely the failure strain and the resultant force based failure criterion. The former is not robust and the latter requires a lot of tests to be done for different designs of the resistance spot welded joints. In the case when the RSW joint has pullout failure, i.e. the failure occurs in the base metal, a material model is used in the present work to model the RSW joint pullout failure by modeling the failure of the base material. Only simple tensile tests are needed in order to use this method while the geometry effects of the joint design and the strain rate dependence of the base material are handled by the material model itself. In order to analyze the failure mode of the RSW joint, a combined methodology using thinning strain failure criterion for the base material failure and force-based criterion for interfacial failure is examined. Preliminary simulation results show good potential for utilizing this method to model RSW joint failure.