Shown is a comparison of the results for a 25 mm2 wire harness with different extrusion heads at unit sizes of 2 mm, 3 mm, and 4 mm. The CAE simulation results show that in various indenter tests, the results of the 4 mm grid size are far away from the experimental results, the CAE simulation results of the 2 mm element have the best fit with the experimental results, and the CAE simulation results of the 3 mm element It is also close to the experimental value. Considering the unit number scale and computational efficiency of the actual vehicle crash model, a 3 mm grid size is selected for CAE modeling of the vehicle wiring harness.
The compression force that the harness of combination 1 can withstand is higher than the test value, that is, the stiffness of the harness in this simulation is too high. , but the target value has been exceeded in the later test verification, which requires that in the early design, not only the target value is used to evaluate the simulation results, but also the corresponding engineering experience must be combined.