Inaccuracy in Structural Mechanics Simulation as a Function of Material Models

The study is dedicated to the accuracy of engineering analyses of virtual prototypes. In particular, it aims to quantify the importance of material models and data consistent with physical tests. The focus is set on the stress–strain material characteristic that is the basis for correct simulation results, and the deviations of its parameters—elasticity module and yield stress—that are assessed. This is performed in three main steps: laboratory measurement of the material properties of a sample material (aluminum alloy), followed by an engineering analysis of a component produced from the same material, using the determined mechanical characteristics. The third step involves physical tests used to validate the virtual prototyping results by comparing them with the physical test results. The material properties used in the virtual prototype are subjected to a sensitivity analysis to determine their influence on the design’s elastic and plastic behavior. The main conclusions of the study are the importance of these material characteristics for achieving an adequate result. A general recommendation is formed that shows the importance of laboratory testing of material properties before virtual prototyping to avoid any influence of factors as production technology or geometry (specimen thickness).