Development of a Universal Spot Weld
Model for Automotive FEM Crash
Simulations
A thesis submitted in fulfilment of the requirements for the degree of
Master of Engineering by research.
Khandoker Neamul Ahsan Noman
B. Sc. Eng. (Mech.)
School of Aerospace
Mechanical and Manufacturing Engineering
RMIT University
August 2007
Declaration
I certify that except where due acknowledgement has been made, the work is
that of the author alone; the work has not been submitted previously, in whole or
in part, to qualify for any other academic award; the content of the thesis is the
result of work which has been carried out since the official commencement date
of the approved research program; and, any editorial work, paid or unpaid,
carried out by a third party is acknowledged.
Khandoker Neamul Ahsan Noman
27th August, 2007.
This work is
dedicated to my parents.
Hosneara Nilufar Nilu
&
Khandoker Hayat Uddin
i
Acknowledgements
I would like to gratefully acknowledge all those who rendered their support
and contribution to this research work in both substance and spirit.
I am very much in debt to Dr. Monir Takla, my thesis senior supervisor, for
his contribution and effective guidance through positive criticism at every
step of my work and for extensive patience with continuous support for the
completion of this thesis. I would like to take this opportunity to show my
gratitude to him. I also gratefully acknowledge the generous support of Prof.
Aleksandar Subic, Discipline Head, Mechanical and Automotive
Engineering, RMIT University, my second supervisor, leading to the
completion of this research project.
I would also like to thank Mr. Daniel Belton, Project Engineer, Holden
Innovation, for his extensive support during the progress of this work and
for the review of the thesis. I would also like to gratefully thank Dr. Thomas
Ting, Business and Operations Manager / Projects Manager, VPAC (CFCP)
for his untiring support for this work and for providing constructive
thoughtful comments during the review of this thesis. I also gratefully
acknowledge the financial support provided by the AUTOCRC for the
completion of the research project.
A very sincere gratitude to Mr. Paul John Mignone, Application Engineer,
SIMULIA Australia, for his extensive assistance in organizing the spot
welding of the test samples. I am also very thankful to him for proof reading
the manuscript of this thesis. I sincerely acknowledge the guidance
provided by Mr. Joseph Kovacs of VPAC (CFCP) for introducing me to the
HYPERMESH software.
I would also like to thank specially the staff members from the SAMME
workshop in RMIT, Don Savvides, Trevor George and Peter Rosewarne for
ii
their assistance in the procurement of the test materials and hardness
testing. A very special and sincere gratitude to Mr. Peter Tkatchyk, of the
RMIT Material Testing Laboratory, for his tireless assistance in developing
the testing setup and conducting the experimental testings.
Last but not least; I would like to thank each and every member of my
family for their continuous support and encouragement throughout the
whole duration of my studies.
