In paint shop, car bodies pass through several hot-air dryers and are heated-up to elevated temperature (∼185 °C). The heterogeneous heat-up behavior of the car body as well as different thermal expansions due to multi-material-design often influence the final part characteristics in terms of surface quality, dimensional accuracy, functional behavior and product safety. The use of novel light-weight and composite materials leads to advanced requirements for the manufacturing process with regard to heat treatment aspects. The implementation of Finite-Element-Analysis (FEA) into the physical validation process enables a reduction of cost and time consuming optimization loops in the pre-series period. The FEA is an important contribution to the understanding of thermal deformation behavior and enables a targeted optimization of product- and process parameter in the early development process. In the present paper, the potential of the virtual distortion simulation to validate thermal distortions of car body structures in the paint drying process are presented. In addition to an exclusive virtual investigation, the interaction between the virtual and physical validation of thermal shape deviations in order to create an integrated validation process is introduced. On the one hand, the potentials of the virtual distortion simulation are based on the early prediction of product characteristics in the product development process, on the other hand the virtual distortions simulation enables efficient analysis times using submodelling techniques. Furthermore, the submodelling method enables investigations of variants and car body derivatives under identical process conditions. As interactions of subsequent processes are not considered in first virtual distortion simulations, an approach of an integrated validation process to include further process aspects is described. Novel metrology enables a continuous determination of shape deviations on physical prototypes along the entire manufacturing process. However, product and process data such as digital reconstructed parts can be implemented into the virtual distortion simulation. This generates synergies due to the tight network of virtual and physical analysis. The coupling of virtual and physical analysis enables new opportunities in terms of computer based statistical design of experiments to identify significant parameters. Because of the availability of simulation models and the knowledge of significant parameters, subsequent numerical optimization runs can be performed. Thus, complex processes become transparent and targeted measures can be defined to increase the degree of maturity in the early product period.
Numerical calculation of thermal manufacturing processes for product and process validation of car body structures in the pre-series period
2012
12 Seiten, 4 Bilder, 32 Quellen
Conference paper
Storage medium
English
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