Abstract: In car crash simulation, the effects of thickness change, hardening and residual stress occurring during the forming process of sheet metal part on the car crash simulation results should be considered. The mesh model transferred directly from the forming equipment is usually not suitable to simulate the car crash due to obvious deformation of mesh, large number and small size of elements. An algorithm to transfer the element variables such as stress, strain and thickness distribution from the sheet metal forming mesh system to car crash forming simulation mesh system is proposed. A calculation program is also developed according to the proposed algorithm. The effectiveness of the algorithm is verified by comparison of one car body B pillar crash result with two different meshes. The algorithm can decrease the remeshing of model and avoid the variables mapping after remeshing. It provides a convenient method to incorporate forming effect in car crash model.

Key words: Crash, Forming, Mesh