Planung Marke Volkswagen Digital Paint Process Simulation. E-Coating and Thermomechanic

Transcription

1 Planung Marke Volkswagen Digital Paint Process Simulation E-Coating and

2 Contents Introduction E-Coating simulation s simulation 4 Summary Page 2

3 Introduction 1. Cathodic dip coating simulations with THESEUS-FE E-Coating electric potentials paint thickness 2. Thermal paint drying simulations with THESEUS-FE Oven temperatures exposure times T(t) Structural mechanics simulations with Abaqus displacements, adhesive curing, stresses,... Paint drying oven Page 3

4 Contents Introduction E-Coating simulation s simulation 4 Summary Page 4

5 E-Coating Basic Information Simulations with Theseus E-Coating paint thickness Sketch of e-coating process in plant E-Coating process as an electrical circuit (anode/cathode) anode + - cathode d: Paint layer thickness d Page 5

6 E-Coating Tests and Validation THESEUS-FE E-Coating paint thickness Real-life experiments using the test box Validation of the E-Coating solver in THESEUS-FE Determining material parameters for the simulation Test Box Software validation Calculating entire BiW Detail Page 6

7 E-Coating Validation Example (Exterior Faces) THESEUS-FE E-Coating paint thickness THESEUS-FE model Doors Measured Simulated Messung Var5_ins I1 I2 J1 J2 J3 J4 K L1 L2 M1 M2 M3 N O P I1 J4 J1 K J2 N L1 L2 M2 M1 P O I2 J3 Page 7

8 d [ m] E-Coating Validation Example (Cavities faces) THESEUS-FE E-Coating paint thickness Measured: Simulated: Außenblech Innenseite oben; elo-verzinkt; Seite2 B B Measured Simulated A A Extremely good correlation between simulation and experiment A B Page 8

9 Contents Introduction E-Coating simulation s simulation 4 Summary Page 9

10 Drying Process studies Optical Measurement of individual process steps Large changes are visible after e-coat drying Simulation opens a window into for optimizing the dryer process 1. After body construction 2. After paint pretreatment 3. After drying process Page 10

11 Drying Basic Information Simulations with THESEUS-FE Oven Paint drying oven Temperature measurement THESEUS-FE model T T crit Measured Simulated Nozzle rows exposure time t Page 11

12 Drying - Examples for Transparent Process Simulations with THESEUS-FE Oven and Abaqus (movie) (movie) (movie) Page 12

13 Drying - Examples for Transparent Process Simulations with THESEUS-FE Oven and Abaqus Simulation with THESEUS-FE Oven Abaqus with User Material for Adhesives Critical areas: t exp < t min T crit t min Exposure time: t exp Final, irreversible deformation Page 13

14 Drying - Examples for Transparent Process Variants of hood support: Abaqus models and results (1) -u z -u z 0 0 +u z +u z Page 14

15 Drying - Examples for Transparent Process Variants of hood support: Abaqus models and results (2) -u z -u z 0 0 +u z +u z Page 15

16 Drying cost reductions through simulation Example: front hood Golf A6 / A7 In the past Innovation Today (since 2011) Paint utilities Experiment s Construktion changes Overall proces time optimization Cost reduction Page 16

17 Contents Introduction E-Coating simulation s simulation 4 Summary Page 17

18 Summary & Conclusions Transparent and safe simulation processes of E-Coating s Early evaluation of production processes Minimization of construction changes Early control over products and processes Significant reduction of trial BiWs All-in-all: Product Optimization + Cost reduction Page 18

19 Thank you for your attention. Page 19