The basic physics of the seam sealing process in vehicle construction has been worked out. Thereby, modeling by computer simulation has played an important role. The rheological behavior of the highly viscous PVC and PUR sealing fluids, e.g., shear thinning, influence of temperature, yield stress, and thixotropy has been studied. Important conclusions with regard to the development of meaningful methods for material testing can be deduced. Another area of investigation was concerned with the heating behavior of the flow in hoses, tubes and in the nozzle. From the VOF (Volume of Fluid) simulations important information on the application on substrate steps and hem flanges can be obtained. The model that has been developed will be used for the development and design of improved equipment and materials as well as for a better matching of equipment and materials. This will have a direct impact on the ecological and economical aspects of the seam sealing process. Based on the results of the CFD flow simulations inside the dosing components, a simple design tool could be developed and launched to calculate the pressure losses and heating performance of straight pipes and tubes. The tool will be further completed with additional components. Moreover, the seam formation on moving targets could be successfully modeled and simulated by applying the Volume-of-Fluid model of the commercial FLUENT code. For the case of round jet application, important results concerning the relationship between seam geometry and process parameters, e.g., volume flow rate, nozzle diameter, etc. have been obtained. Furthermore, some characteristics of the application of more complex geometries can be demonstrated. Nevertheless, additional developments are required to convert the method into a real design tool. In the near future, the developed methodologies, programs and tools may be applied to a number of similar processes, such as the application of adhesives, underbody sealants or sprayable insulating materials. However, an essential requirement is the availability of an accurate rheological model for the specific materials.
Simulation of the automated seam sealing process: fundamentals, state of the art and outlook
Simulation des automatisierten Nahtabdichtungsprozesses: Grundlagen, Stand der Technik und Ausblick
2005
12 Seiten, 10 Bilder, 4 Quellen
Aufsatz (Konferenz)
Englisch
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