982311 Fatigue Life Prediction of MAG-Welded Thin-Sheet Structures Mikael Fermér, Magnus Andréasson and Bjérn Frodin Coppi © 1998 Society of Asomative Engin, ABSTRACT [A fiite-olement (FE) based method for numetically pre- cing fatigue ite of MAG-welded thin-sheet structures thas been established and tested. The method uses nodal forces and moments calculated along the weld line, tegother with an anslytical expression for the structural sires at tho weld to9, The calculated stress is used together with an experimentally datarminad Wahler, of S- NN, curve. A “stiff” welded joint with stuciural stress dominaied by membrane forces Is found to have a ‘stooper SN curve than a “loxiblo” joint with structural stress dominated by bending moment. Al test rosulls were seen to lle Close to one of two diferent S-N curves, ‘The proportion of bending stress over total structural siress could be used for choosing the appropriate S-N INTRODUCTION Mechanical FE analyses of welded structures are per- formed on a daily besis in the automotive industry. One objective is to estimate the fatigue strencth, which for thin-sheet structures is mainly given by the strength of the joints. Different metnods tor predicting fatigue lite of spot-welded thin-sheet structures have been proposed in recent yeers, and ere in daily use al several car compa ‘ies [1-4]. Tore fe a general tend today, however, 10 use hydrofocmed beams as a complement to beams made from spot-weided pressed sheets. These beams Nave no flanges, which means that fastening arrangements other than point joints may have to be used. One possttilty is, te use MAG-welding. There is also a trend towards cara. built on space frame siructures, which are likely to bo made of MAG-welded tubes. MAG-walds can also ba found. In chassis component's. (motor subframes, tink 1280 \Voive Car Corporation farms, bus chassis) and in several other engineering ‘applications, “The actual stiess siate n a welds aut or, in practice, maybe impossibie to determine due to unknown residual stresses, rendomly distrbuted defects, undercuts end variations in weld profile. Thorefere, the fatiguo Ife for welded structures is mes! often based on experimentally determines Wohler or S-N cunes, where a sutaoe ‘structural stress, 5, is relaied to the number of cycles 10 failure, N. ‘There le an enormous amount of ltarature In the field of {fatigue Ife prediction of welded thick plata structures for ‘off-shore and ship applications etc, There are also svict design rules available for a number of welded geometties. [5], The approaches for thick plates are, however, not adoquate for ightor thin-sheet structures. Thore is vory litle work published inthe field of MAG-welded thin-shaet structures [6] (7. Inthe present study, an FE-based method for numericaly predicting fatigue io of MAG.wolded thin-sheot struc- {ures has been established and tested, The method uses ‘nodal forces and moments calculated along the wold Ina, together with an analytical expression for the structural stress a the weld too. The calculated stress is a geo- ‘motieal (hot-epot) etrose and ie used togothor with an experimental determined S-N curve. The geometrical stress does not include local effects, out Is assumed to be highly related to the stress state that leads to fatigue faliwe. One advantage with the proposed method is that fa rather coazee mash can be used without losing teo ‘much accuracy in predicted fatigue ile. The method has been found to give good resuits also at critical locations, ‘such as weld starts and weld comers, without the need for element intonsive refinements.Test results, from 8 diferent stee! specimens (ested at Volvo and elsovinere) with sheet thickness botwoen 1.0 ‘and 3.0 mm and load ratios betwoen = 0.1 and A have been used to verity the proposed methodoogy. FE MODELLING ‘The main purpose isto create an FE-based methodclooy thalle geometry edependent and smpe to Use. It shOUlS be possible to use a rather coarae mesh without lesing accuracy in fatigue resus The proposed mthod calle for the following 6 meshing, rues! + The etructure as wal asthe wolds are modelled wih “4node shell elements, + The sheeis are described by ther mean surfaces. + The nodes of the shell elements resreseniing the wold are ofiset by 12 from the location of the weld 100s, 660 Figure 1(@). + The thiokneas of the weld elements is the same as the elective throst a, See Figure 1a + The element length is about 10 nvm. + Small radi are not inched in the modeling Theeo rulos should not eauso any major probleme, and do not resull in any complicated and elementiniensive Torinoments closa to the weds. An example of 2 fet wold going around a comers chown in Figuro 1(). ANALYTICAL MODEL For welded thi-shect structures cracks are most often Tocated at the weld toes and orientated along the weld ling, is than quite natural to use the normal sess, orpendicular to the weld tno as structural siross. This ‘stress is caused by bending moment along the weld line ‘and by normal force perpensieular to te weld tne. With a line moment my (N/m anc & Tne force ny [Nin] the ‘Structural stress can be calculated as 12 my z 7,0) rp + 29) = oP 1) a“) 1281 rode 4-coda shat amen crack cation @ (b) Figure 1. (a) Cross-section of weld connection batwaen 2ihin sheets, Four-ode shell elements Postioned along cena Ines are used to ‘model the connection. Structural teases o 1, {and 6.9 ere shown together nth typical crack locations. 0) Part of an FE model ot a continuously welded structure cortaining a sharp corner Here, op is bending stress. o, normal sess, 2 te dis- tance trom the mean surtace in the local z-direction and 1 tho shoot thicknoes. Tho ditions in Equation (1) aro according to Figure 2, The eaculated stess, 6, inches tne most important informaton about the stress stato at the weld toe: It does not include very local effects: on the contrary, # more cl a geometrical siress at a ciiical Fooation (hot epo!). Tho caleulatod strose ic, howover, assumed to be strongly relaied to the stress slate thal Toads 10 fatigue falure, Two elamenis fom Figure (6) ‘are stugiod mero in dotallin Figure 2. ‘A rato, F, between bending stress anc: total structural ‘tress ia inroduood and dotinod in Equation (2). This ratio is later used to separate normal force dominated lead eases from pending cominated load cases. eo gftg teres €4.2)CCaeulated nodel moments, My {Nn}, ard foro06, Ny INL acting on each indvidual sierent (GPFORCE in MSC! NASTRAN™) can be iransformed fo Fre momerts my) [Nmim], and tine forees m4) (Nm). The vant 1s assumed be linear along the wold ine. For clement £9 in Figure2 this can be wrtlen as: 7 Figure 2. Element length thickness, ¢ and nodal forces and moments in weld toe elements Used in stiess calculatons. For a continuous ‘wold there willbe 2 values of ¢, for each node. lis proposed to use the largest value. The ootdinate system shows the local direction of ‘the eleronis. ‘The siusural tess al the lop suave (z= #2) can be ‘calculated at the two node poinis, 9: and ge", by using Equations (1), (3), (4) as: 2M} 2 ni og a” ay OL aye on ye fy €0.5) D9 afi yea M2 2m el 812" Tey y * E46) For @ continuous weld there wil be two values of «for ‘ach nodo along tho weld (see Figure 2). its proposed: here that the maximum magrcude, wth maintained sign, be used for each node. WELD STARTS AND WELD CORNERS elo starts and weld comers cause stress concentr tions duo to local goometriel eects. With the propo ‘method, ne extra refinement is needed at these points. 1282 Four diferent stross values aro calculatod at neld starts and weld comers (see Figure 3}, One value is calsatod in @ement Ein element E©) siructural stiesses are calculated in two diferent drectons parallel to the ele ment sidos. These strosees aro ealouatod using Equa- fon (5), with forces and moments as described in Figure 3. AS an example, structural stiesses og and 13 212 ‘alouated as: ea? 2 ne} 2 Be 0.7) v2 2 wi) 2? Ne 9-H R Dy rnd €<.8) Note that aliferent lengtis ere used to calculate the stresses in the two directions. The stresses in elament E®) aio calculated in tho eamo way as for element E' The maximum magnitude, wih maintained sign, ofthese calculated stresses is used (0 define the structural stess al the weld sta, or the weld corner, or both NUMERICAL EXAMPLES Structural etresces have boon celoulatod for a number of ferent joints. According to provisly defined meshing rules, both shocts and weld seams were modelled with 4 rode shell elements (CGUADA in NASTRAN) A few 3- odo shell elements (CTRIA3} wore used in the modéle, but not in the veld areas. An element size of about 10 ‘mm was used inthe mode's where possible. ) Figure 3. FE model of (a) start or and and (b) sharp ‘earner of filet weld, Directions of ealeulatod siresses are shown. (c] Moments, forces and element lengths used in structural stress calculationTJOINT SPECIMEN —‘wonty Tjoint specimens wore manufactured and fatigue tested for this project. An FE ‘model of a continuously welded Tyoiat specimen (called “Ta) with boundary conditions and load point is shown in Figure 4. An FE model of an intermittently welded speck ren (called 75) Is similar to T-a but wih the shell ele ments next to the comers removed trom the wel, Structural etosses wero calculated along the wold toos of beth the bace and the atub. Tho highest stosces wore ‘obtained in the base, and ave given in Figure 5. ub 40xE0x1 6 mm oF 40x6%2.0 mm base 40x60x1 5 mmo, 406020 mm # > Figure 4, FE mode! of continuously welded Tint ‘specimen (called T-). A point oad, Fy, ‘appied in tho x-craction via a rigid ‘connection. The specimens rigly fixed atthe lower outer part ots base, Sheet thickness is 150/20 mm. isthe distance along the wal. ae Figure 5. Structural stresses calculated along the weld {oe of the base of continuousiy Welded (7:2) and intermittently welded (Tb) Tyoint ‘specimens. Highest structural stresses ore ‘dominated by bending moment (r= 0.98). The distance along the welds defined in Figure 4 GRUGIFORM SPECIMEN ~Two types of enuciform ‘specimens (called C-2 and C-b) have been fatigue tested by Volvo Bus Corporation [8]. thir, similar, specimen (Called C-c) has been tested by Volvo Technological Development [9]. The FE medels and calculated struc- tural stresses for those cruciform spocimens aro shown in Figures 6 to 8 belon. Specimen C-c's diferent trom specimens C-a and C-bin ‘that the Icad is not drectly transmitted via the weld line. For specimens Ca and C-b calculated stresses were found to be highest along tha wold toes of the verteal bbeame. For epesimen Cc, the highest strescos wor found in the horzontal bear, 27kN Figure 6. FE models o! eruclorm specimens made from FHS profiles, wn cimensions 80 x 40 x3 mm Etfoctve thcat 2 6 3 mm. Specimen C-2 is loaded in tension (5) wnareas specimen C-b 's loaded in tension |F,) es woll asin bending (F). isthe distance along the weld Figure 7. Structural stresses calculated along weld toes ‘of vortcel beams in specimens C-a and C-b. Highest structural stresses are dominated by membrane forces ('<0.29). The distance along Ihe welds defined in Figure 6,40-4002 mn fective throat ce Figure 8, FE model of erucform spacimen C-o with boundary conditions and loading case. Erfectve throat ais 2mm. &is the distance along the weld, Figure 9. Structural svess calculated aleng the weld tos ‘ofthe horizontal beam ct specimen C-< Highest structural strasses are dominated by membrane forces (r=0.20), The distance along ‘tho wold is defind in Figure 8. EFFECT OF ELEMENT SIZE ‘The effect of element size on calculated structural stress has been investigated using the Tjoint specimen and an Hesheer specimen. The geometry ofthe THoint specimen inoludes sharp corners, where large siress con ‘centrations and local Geformation appaat. in the H-shear specimen, on the other hand, the weld is exposed to ‘ally unform loss. Four diforont mosh sizes wore used forthe Tjoint spoct men, and 2 diferent moon size wore used for tho H: shear specimen, The FE models of the Tjoint specimen are shown in Figure 10, where 4 is 10 mm. Due to the geometry ofthe Toit specimen, several elements have a rectangular shape. This appies particularly for the coarse meshes. Calculated structural stresses along the weld ine of the base of the Tjont specimen are shown in Figuie 11 Daspite te tect that the alifarerce in elemant size is large, the structural stress along the weld seam is rather Uniorm tor the stiorent mashes, This can be compared 1284 to node stresses aleng the wold toe caleuatod from ‘mont stresses outside the wold line. Calculated mani ‘mum principal stresses are far too low, and forthe finest ‘modal only 40% of the calculated structural sess using the proposed method. With the coarse mesh. the results ‘were naluraly much worse, and the maximum siress was hot even located at the right roce. Calculated structural stresses for ihe H-shear specimen ‘ware constant ‘or the 3 alomert sizes analysed, for Eoint specimen (T-3) with ifarent element ses normalized to =10 mm. Variablo in (4) indicates etat pent for calculations, S-N RELATION FN relations (orce, F. versus numbers of cycles 10 tak ‘ure, 1) irom real fatigue tests have been used together ‘with maximum structural stresses, S, calculated using the proposed method to establish S-NV relations S-N rel tions based on results from all 8 specimens stucied in this project are prosented in Figure 12. A visible crack was usod as fall eritoria in al toste. ‘Goometry and tost results for 2 standard H-shoar spect mens wore collected from Reference (10). 5 Figure 11. Structural stross curves for Tjoint specimen (Ta) calculated with four cifferent element ‘sizes, The distance along the weld is according to Figure 10 ().“Tho results lio close to 2 differant S-N curves. Common for the test points belonging to the upper S.N cunve is, that the maximum structural sross is dominated by bond= ing moment along the wold Ine. For the loner, stoeper S- ‘Neurve, on the other hend, the maximum stress is dom- rated by normal force perpendicular tothe wela line. It is suggested that the lower and steeper curve should be used for 0 < r< 0.5, and the upper and flater curve ‘should be used for 0.5 < <1, The ratio 7's defined in Equation (2), Both curves are valid at load ratio = -1 (alternating load) and for the interval 104 < N< 2-108, The Compensation for mean stress is given beta. eet ne ep Figure 12. Altes resus plotted against two $4 curves. FFoints betonging to he upper curve have a ‘maximum structural siress dominated by bending moment. Points belonging tothe ower curve have maximum structural stress dominated by normal force. All results are ‘converted to load ratio A= 1 according to Equations (12) and (19). Load ratios, A. and ratios, r; defining the proportion of bending stress over total structural stress are given, “The linear relationship between structural stress ampli- tude, 9, and the number of cycles to failure, N, (the so called $:N relation) is defined as: 1k a0 4.9) Hore the value of kdeserbes the slope of the cune and |g given for te 2 SAV curves In Fights 12. As a wu of trum it coula be said that the sone, K Is about 4 for "sir welded Jons, and about 7 for “exibie" welded Joints, Further tosis have to be perormed to Investigate te area between the 2 curves. EFFECT OF MEAN STRESS ‘The S-N relation has been determined for A = -1 (ater- nating force). A new compensated stress ampltude ‘corresponding Io A= -1 has 10 be calculated for those 1285, tests where Ris not equal to-1. This can be done using a Haigh diagram. The folowing 2 squators nave be Lsod fo osiablish a Haigh clagram that should be valid for welded shoot structures (5) (Eq. 10) a1) Using these 2 equations, 2 mean senstivty factors 1M,=0.25 and MMy=0.097 can be determined. THs leads 10 Equation (12) 0. oA(F 4.12) og(Fi=-1) = (1M) 4.13) Here o4(F=1) is the equivalent stress amplitude at load ratio A= -1 fr each eycle with amoitude ¢, and mean DAMAGE CALCULATION Damage calculations can be carried out for every node ‘along the weld seam. For each node the stress history ‘should then be rainflow-oycle counted to form a mean: range histogram. A random lead history is theroby reduced inio a sories of docrets ovonts of constant ‘amplitude. According to the Palmgrer-Miner cumulative ‘damage rulo, the damage caused by different events of ‘constant stress amplitude can be linearly accumulated, ‘The fatigue failure wil oceur when the total damage = 1 It chould bo nected, however, that tho $-N curves in Figure 12 are givan for Fi =-1 (alternating stross). The raintow cyeies then have to be converted to equivalant stress amplitude for R= -1 before the damage is calculated and summed The mean stress conversion is described above, ‘As shown in Figure 12, 2 diferent S-N curves are fottained for MAG-welded thin-sheet structures. It Is, found that the slope of the S-N curves ‘s strongly Inked 1 te ratio r= lal / kta. The velue of the ratio ris ‘given by the geometry and the Iced case. This means ‘hat the ratio r might change for a specimen exposed to ‘non-proportionet loading. Fo large variations of rt might be difficult to know wich SV curve to use, Some numerical tests were periormed with specimens loaded in diferent directions. The aim was to find a case ‘where the r value changed a lot with loading direction. It ‘seems, however, thal every point along a weld seem is, celther “sti” or exive” whatever the loading case. Thus a damage calculaton using a single S-N curve should be possible.Further physical and numerical tests on specimens exposed to non-proportional loading histories are needed incrder to validate the proposed method, ‘SUMMARY ‘An FE-based method ‘or numerically previcting fatigue lives of MAG-welded thin-cheet sttuctures has. boon. ‘stablished and fasted. The method works well for the load cases analysed in this work. It has been found 10 give useful results at ctlical locations, such 2s weld starts and weld corners, without the need for etemen- intensive refinements Test results from 8 diferent welded steel specimens have Deen used to very te method. was found that there fs {strong connection between the bending moment along tho weld line and the slope of the S.N cure. All tost results could be titted to 2 citterent curves. The SN curves are established for sheet thicknesses between 1 ~ 3 mm. This interval does not seem to require ary com- ensating factor for sheet thickness. Hoviever, this may have to be investigated further for thicxnesses outside ‘ns interval, A ratio, , deffing the ratio of bending stress over total structural stross is intioduced, and used for chocsing appropriate S-N curve. Welded joints of the studled type are often made in alu minum. The proposed method for fetiguedife prediction ‘should also be valid fer other materials than steel ACKNOWLEDGMENTS ‘The manufacturing and testing of the “Hoint specimens was financed by the Volvo Fatiquo Design Group, Discus sions with Mr Lars Hjertonsson, at Valve Bus. Corpora- tion, and Professor Lennart Josefson, at Chalmers University of Technology, are graiefully acknonedged. REFERENCES 1, Rupp, A. Sidr K., and Grutisic, V, Computer Aided Dinonsicning of Spo! Welded Automotive Structures, SAE ‘Technical Pader 990711, In SAE International, USA, 1995, 2. Heyer, P_and Fermér, Mt, A Spot Wold Fatigue Analysis ‘Moauio 1 the MSCATIGUE Environment, 1396 MSC World Usore’Conieance, 1006, 3, Sheppard, S_ ©, shen, ¥-C, Bal, Z. and Schmic, \., D., Resistance Spot Wolds Strctsres in Fatigue, Papat pro: ened at IDEC ‘86, Advanced Technclogies & Processes, ‘Actomctve Technology Group, Michigan, 1608 4. Heneysson, Hof. and Aberson, C., Fatigue Lile Prediction ‘of Spot Welded Thin Sheet Sirucures - Theory ard Exp iments, Dipoma Thesis, Division of Solid” Mechanics, Chaimers University 0! Tecnnoo3y. Gothenburg. Swecen 1996 5, Bergstrom, 8. et a, Plthandboken, at korsiruera och ‘verka | Péghdllat plat, SSAB Turnplat AB, oocond oc tton{in Swedish, Borange. Sweden, 202 99.1690 6. Feyard, J.-L. 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