Affiliation:
1. Fraunhofer Institute for Machine Tools and Forming Technology IWU
2. Porsche Leipzig GmbH
Abstract
The use of FEM (finite element method) to assistant in ramp-up processes of car body construction lines is increasing, thanks to developments in recent years [1-3]. Car body manufacturing begins with sheet metal forming, while in subsequent steps the inner structures of the vehicle are assembled and connected to the outer skin by hemming. With reference to the current state of the art, there is no methodology which can reliably predict the dimensional accuracy of body parts through metal forming [4].Additionally, several methods to predict the distortion of joining and the dimensional effect of clamping during the assembly process were presented and validated [4-11]. Dimensional effects of the clamping process are basically the result of a deliberate alignment, other than the given values of construction to compensate dimensional inaccuracy of single parts from the body shop. These deliberate alignments are generally effected through a translation of clamps and pins in the clamping device. Until now, most of the methods of clamping and joining simulation presented have been verified using academic samples.In this report, the quality of forecasting in real problems during a ramp-up process will be verified and expanded. As part of a national project, co-funded by Sächsische Aufbaubank (SAB), the potential of FEM to assist in the ramp-up process were reviewed in a cooperative effort between Porsche Leipzig GmbH and Fraunhofer Institute for Machine Tools and Forming Technology (IWU). Furthermore, it will be shown that developed methods are able to represent the influence of deliberate positioning of clamps in complex samples. For the first time the quality of forecasting through the translation of locating pins is numerically and experimentally qualified.
Publisher
Trans Tech Publications, Ltd.
Subject
Mechanical Engineering,Mechanics of Materials,General Materials Science
Reference8 articles.
1. A. Eckert, R. Neugebauer, M. Rössinger, Application Limits of a Method to Predict Distortion Caused by Mechanical Joining Technologies in Cad Body Construction , 8th international conference and workshop on numerical simulation of 3D sheet metal forming process – Numisheet (2011).
2. A. Eckert, Prognose der Maßhaltigkeit punktförmig mechanisch gefügter Karosserieanbauteile, Dissertation, Chemnitz, 2012, p.46.
3. W.G. Drossel, M. Wahl, F. Schulz, R. Mauermann, W. Schützle, P. Ackert, Improving surface based clamping simulation by measuring the position of active surfaces during the clamping process, ESAFORM (2012), Key Engineering Materials Volume 554-557.
4. J.A. Camelio, S. J. Hu, D. Ceglarek, Impact of Fixture Design on Sheet Metal Assembly Variation, Journal of Manufacturing Systems Vol. 23/No. 3, (2004).
5. W. Cai, S. J. Hu, J. X. Yuan, Deformable sheet metal fixturing: principles, algorithms and simulation, ASME Journal of MFG Science and Engg. V118, (1996).
Cited by
2 articles.
订阅此论文施引文献
订阅此论文施引文献,注册后可以免费订阅5篇论文的施引文献,订阅后可以查看论文全部施引文献