Simulation of joining technologies to

support JLR new model development

Dr Li Wang (PhD, CEng, MIMechE)

AME, BIW, Joining Technologies
Contents

• Introduction
• Joint feasibility simulation
• Joint performance simulation
• Simulation to assist design & production
• Summary and further plan
Jaguar: LWV - a wonderfully rich heritage

Jaguar XE
Revealed

• Jaguar, first 60 years was all about making it light for speed & performance -
vary much focused on racing & low volume performance cars
• Light Weight Vehicles commercial & high volume products started from 2003
Jaguar all aluminium XJ
Land Rover: LWV - a wonderfully rich heritage

• 1948 Land Rover was clad in aluminium alloy due to steel shortage
• 1989 Discovery had aluminium outer panels attached to steel internal frame for
corrosion resistance & light weighting
• 2012 Rang Rover is an all aluminium vehicle
Background
- SPR in JLR Light Weight Vehicles

Jaguar XJ (2003) Jaguar XE (2015) Jaguar XF (2015)

Jaguar F-Pace (2016) Jaguar F-Type (2014)

Discovery (2016) Range Rover Sport (2013) Range Rover (2012)

Background
- RSW in JLR Light Weight Vehicles

Range Rover Evoque (2014) Range Rover Evoque Convertible

(2016)

Resistance Spot Welding (RSW) is the

main joining technology for
• JLR steel body structure vehicles
• Steel parts in Al vehicles

Discovery Sport (2015)

Background - JLR joining technologies

Self piercing riveting (SPR) and resistance spot welding (RSW) are the two main
joining technologies in JLR
• SPR --- Al / Al Al / Steel Steel / Al (2T, 3T, 4T)
• RSW --- Steel / Steel (2T, 3T)

SPR RSW

Both SPR and RSW:

Requires intensive laboratory tests to confirm joint feasibility and performance
Requires a large amount of materials and labour hours for coupon test
Human errors difficult to avoid during measurement
Introduction - Simulation

Processing

Simulation

Structure Properties

Connecting to all available CAE tools within JLR

to support vehicle design and flawless launch in
a virtual enterprise.

8
7
6
Force (kN)

5
4
3
2
1
0
0 2 4 6 8
Stroke (mm)
Introduction - Simulation

Simulation for:

Joint feasibility study

Deliver process parameters
Joint performance prediction
Fast response to materials/process change
Investigate joint failures in teardown vehicles
Assist to vehicle design
Innovation of new joining techniques / new materials
Contents

• Introduction
• Joint feasibility simulation
• Joint performance simulation
• Simulation to assist design & production
• Summary and further plan
What does joint feasibility mean

Example of parts joined by

the same SPR gun Stack 1
2.5mm 5xxx Al

2.5mm Cast Al

Stack 2
3mm 6xxx Al

2.5mm Cast Al

Stack 3
3mm 6xxx Al
Selection of a common
2.0mm 5xxx Al
rivet/die combination
Stack 4
2.0mm 6xxx Al
2.5mm 6xxx Al

Stack 5
3mm 6xxx Al
Stack 6 3mm 6xxx Al
2.0mm 6xxx Al
1.2mm 5xxx Al
11
Feasibility evaluation

12
Feasibility evaluation

13
Issues of physical coupon test

30 minutes per section

Over 5,000 sections for a new model

TIME 2,500 action hours COSTS

Spending over £1 million

Forming, Aging, Surface conditions, Temperature, Fracture mechanism, C-

frame, Gun misalignment
CAD Models for SPR process

Punch

Rivet
Bank holder

Substrate
Die materials
JLR Solution: Finite Element Simulation

Challenges – Not just use a software

1 Short CPU time – 10 minutes

2 High accuracy - >85%

3 Suitable for industrial applications

16
RSW Simulation 17

Preparation of input data Running simulation Evaluation of results

Define materials properties Call the data file which Open the solved data file
and geometry has all the required An overview of
information parameters, thermal
Define the machine Define a location for history, nugget size, etc.
(welding) settings storing the calculations). Time-temperature plot at
Define simulation controls Start the solver a particular location
RSW Simulation - Effect of electrode worn

Electrode worn
New
Worn1
Tip geometry
Worn2
change
Worn3

Welding current
& force affected

*Electrode geometry can be self designed

Contents

• Introduction
• Joint feasibility simulation
• Joint performance simulation
• Simulation to assist design & production
• Summary and further plan
 From SPR to strength test simulation

Run 2D SPR simulation

Expand 2D SPR results to 3D

Apply test geometry

Re-mesh for 3D model

Apply motion
SPR strength tests simulation

Peel test
Shear test

Cross tension test

Contents

• Introduction
• Joint feasibility simulation
• Joint performance simulation
• Simulation to assist design & production
• Summary and further plan
Simulation to assist design & production
- Effect of materials properties variation?

T4 condition of 6xxx Al alloy suffering materials properties variation during

natural ageing
Simulation to help identify the effect and give solutions

Ageing effect of a JLR 6xxx Al alloy Effect of Al condition on SPR feasibility

Yield Strength (MPa)

Ageing time

Fail
Pass

Ageing (month)
As received condition
Simulation to assist design & production
- Effect of edge rivets?

Edge rivet Normal rivet

• Simulation to predict the strength sacrifice

for edge rivets
• Assist to vehicle design & production plan
Simulation to assist design & production
- Fast response to change

• Materials delivery and preparation time can be saved

• Fast response to the materials / design change
• Accelerate the feasibility study for new materials
Contents

• Introduction
• Joint feasibility simulation
• Joint performance simulation
• Simulation to assist design & production
• Summary and further plan
Summary

Avoid late
delivery

SPR Cost saving

Finite Element
Simulation
Environmental
friendly
RSW

Processing
Fast response
to any change

Simulation

Structure Properties
Further development

Ultimate goal: Input stack information output feasibility prediction

Failure model SPR

Stack 1 Friction model specifications
information Stack 1
Rivet & Die definition Rivet & Die

OK
Stack 2 Stack 2 Common
SPR simulation Rivet & Die
information Rivet & Die
NOK
Flow curves for
sheet, rivets;
CAD models for
Stack ‘n’
Stack ‘n’ rivet, die, blank Rivet & Die
information Materials information
holder & punch
SPR CAD information

We can make it even faster…

 Thank you
Danke
謝謝
Grazie
Merci
Gracias
Contacts:
[email protected]