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<p>This study addresses the residual stresses generated during multi-process chains—including stamping, welding, and aging—in the manufacturing of automotive chassis components. An integrated method for synthesizing and simulating initial stresses is proposed. By developing a coupled simulation workflow and an efficient stress mapping algorithm, the multi-process residual stress fields are systematically synthesized. Bench test validation demonstrates that this method significantly improves the accuracy of fatigue life predictions, revealing that welding-induced residual stress is the dominant factor affecting fatigue damage. The approach provides an effective solution for durability design and process optimization of chassis components.</p>

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A strength and durability initial stress simulation synthesis method for the stamping-welding-aging process of a sheet metal structure

  • 期刊论文

  • 发表日期：

    2025年10月10日

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  • Ying Li,
  • ZhiYang Chen,
  • WeiYuan Sun,
  • Li Hu

摘要

This study addresses the residual stresses generated during multi-process chains—including stamping, welding, and aging—in the manufacturing of automotive chassis components. An integrated method for synthesizing and simulating initial stresses is proposed. By developing a coupled simulation workflow and an efficient stress mapping algorithm, the multi-process residual stress fields are systematically synthesized. Bench test validation demonstrates that this method significantly improves the accuracy of fatigue life predictions, revealing that welding-induced residual stress is the dominant factor affecting fatigue damage. The approach provides an effective solution for durability design and process optimization of chassis components.