Test Based Modeling Approaches for Vehicle Cooling Modules

This paper presents different modeling techniques to verify and validate the local and global structural deformation for the radiator package and cooling modules. The verification and calibration work for the investigated numerical models is based on a simplified punch and bending test (crush) procedure. The main focus of this work is the proper test definition and in parallel the gradual generation of the FE-Models for the numerical simulation. On one hand this was represented by the identification of relevant response features from tested specimens and on the other hand, the interpretation of this information according to the LS-DYNA modeling capability. The purpose was to generate equivalent numerical models for each cooling component in respect to the test results, in order to get a combination basis to obtain one suitable radiator-assembly for the validation effort of the full car crash scenario. The modeling approach is based on the simplified test procedures and follow, a pragmatic engineering practice. The model has to meet the best compromise concerning: engineering effort - modeling work in order to generate a robust numerical model confidence level - phenomenological relevance computational resource