July 29, 2015

Kendall MooreVehicle Integration & ValidationDurability & Development OperationsGraduating May 2016Mechanical Engineering

Kendall Moore Hometown: Newport News, Virginia

Rising 5th year, Virginia Commonwealth University, Richmond, VA

Degree: Mechanical Engineering, minors in Math & Physics

RA & Extracurricular Involvement (social justice, cultural, leadership/honor)

Interests: outdoor activities, live music, Game of Thrones Professional Experience

07/29/2015 2

Opportunities

CPG Ride and Drive

FCA Intern Social Events Walter P. Chrysler Museum

Mack Engine Plant Tour Cultural immersion Day

Road Test Simulation Lab Mechanical Life Testing Lab

Data Acquisition at Chelsea Proving Grounds

07/29/2015 3

407/29/2015

Background

Resistance Spot Welds Primary connection for joining vehicle body structures ~80% body structure durability issues are at resistance spot welds

Typical Loading Conditions and Failure Modes of Spot Welds Lap Shear Coach Peel

507/29/2015

Project Description

Investigate sensitivity of spot weld modeling with CBAR and CWELD elements on stiffness and fatigue life predictions

• Compare to physical coupon test results• Help harmonization activity

Testing Parameters: • Element quality (CBAR) : best, worst• Connection configurations (CWELD) : best, worst1, worst2• Sheet metal thickness: 1.0 mm, 1.5 mm/1.6 mm• Mesh size: 4.0 mm, 5.0 mm, 6.0 mm• Loading condition: lap shear and coach

peel

CBAR weld element CWELD weld element

601/01/2015

Actual Testing/ANSA Model Set-up

Lap Shear Coach Peel

MTS Coupon Cyclic Loading Setup

Lap Shear Coach Peel

Coupon FEA Models

Spot Weld

Constraints

Force

707/29/2015

Spot Weld Element Connection Configurations

CBAR Best CBAR Worst

CWELD Best CWELD Worst 1 CWELD Worst 2

CBAR • Best- Symmetrical• Worst- Skewed

CWELD• Best- Centered and aligned• Worst 1- Diagonal• Worst 2- Parallel offset

807/29/2015

Analysis Procedure

ANSA Preprocessing

• Apply Surface Mesh

• Apply Boundary Constraints and Loads

HPC SERVERRun NASTRAN job

• Utilizes Open Terminal to solve input deck at provided parameters

HYPERVIEWSolution Viewer

• Stress Solution

• Displacement Solution

nCODEPostprocessing

• Life fatigue predictions

• S-N Curves

Report• Results discussions • Conclusions

907/29/2015

Results – Stiffness

• CBAR model predicts lower overall stiffness ratio, CWELD predicts higher stiffness ratio

• CWELD Model provide stiffness ratio closer to 1 than CBAR Model.

CBAR BEST

CBAR WORST

CWELD BEST

CWELD WORST1

CWELD WORST2

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

0.77

0.85

1.20

1.05

0.90

Ratio to Test

Elem

ent C

onne

ctio

n C

onfig

urat

ion

1007/29/2015

Results – Fatigue Life

• CBAR predicts fatigue ratio closer to 1 compared to CWELD

• Overall Fatigue Life is not sensitive for both CBAR and CWELD models, less than 10% variation between the Worst to the Best element connection configurations.

CBAR BEST

CBAR WORST

CWELD BEST

CWELD WORST1

CWELD WORST2

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

1.13

1.13

1.25

1.25

1.15

Ratio to Test

Elem

ent C

onne

ctio

n C

onfig

urat

ion

1107/29/2015

Element Size Influence

CBAR BEST CBAR WORST CWELD BEST CWELD WORST 1 CWELD WORST 21

1.1

1.2

1.3Fatigue Life

4mm

5mm

6mm

Element Connection Configuration

Ratio

Ave

rage

• Spot-weld structural stiffness and fatigue for CBAR and CWELD models are not sensitive to mesh element size.

CBAR BEST CBAR WORST CWELD BEST CWELD WORST 1 CWELD WORST 20.60

0.80

1.00

1.20

1.40 Stiffness

4mm5mm6mm

Element Connection Configuration

Ratio

Ave

rage

Element Size

Element Size

1207/29/2015

Future of Project/Takeaways Contribution

• Obtain sensitivity results for Stiffness and Fatigue Life for CBAR and CWELD element types to be utilized for future conclusions

• Played a role in prospective completion of harmonization project

Next Steps:

• More parameters (element size, element quality)

• Full-production model analysis

Takeaways

• Analysis software experience

• Transferrable skills

• Exposure to global company in Automotive Industry

1307/29/2015

The Future and Beyond!

Complete Undergraduate program (VCU)

CIE Program

Master’s Degree Mechanical Engineering

Engineer in Training(EIT) EXAM

Studio Engineer/Durability Engineer

1407/29/2015

THANK YOU

Joseph Vedrody

Wilson Zhang

Dan Asmus

Michael Rowley

Cindy Gates

Joseph Johnson

Genna Edmonds

Nicholas Posey

Ram Bhandarkar

Jennifer Choi

Vanessa HawkinsBryen Irving

Stephen Scott

Vincent Marsella

Jessy Robison

Christopher Duke

Kipp Owen

Dr. Mike Guo

Stephen Tatangelo

1507/29/2015

QUESTIONS?

Thank you for your time.