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Digital process planning of joining by numerical models in the automotive industry
KTH, School of Industrial Engineering and Management (ITM), Production Engineering. (Joining technology)ORCID iD: 0000-0002-9849-1754
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The automotive industry is striving towards reduction of greenhouse gas emission by reducing product weight and improving fuel efficiency of their products. The introduction of lightweight materials have imposed greater pressure not only on the product development but also on manufacturing systems. One integral aspect of manufacturing systems, which is meeting these challenges is joining technology. In order to achieve successful joining of new automotive products, joining process planning must be equally successful.This research aims at improving process planning of joining by introducing digital tools into the process planning work method. The digital tools are designed to reduce lead times and increase accuracy of the process planning to realize more advanced, complex and environmentally friendly product solutions in the vehicles of the future.The research has two main focuses. Firstly, the joining process planning structure and organization have been analysed. The analysis has identified specific instances where digital tools can be introduced to improve the process planning and make it more efficient. Digital tools, such as numerical models for prediction and databases for re-use of knowledge, have been suggested for the process planning. An assessment of the impact of the introduction of these tools in an industrial test case has been performed to show the possible reduction in lead times.Secondly, geometrical distortions due to laser beam welding have been investigated, both by experimental trials and numerical modelling. The influences of design and process parameters on the distribution and magnitude of geometrical distortions have been established. Numerical models of different modelling detail and complexity have been developed and evaluated in order to find modelling approaches with reduced computation times aimed at industrial implementation. The predictive accuracy and computational efficiency of the numerical models have been assessed and evaluated with regard to industrial implementation.

Place, publisher, year, edition, pages
KTH Royal Institute of Technology, 2017. , p. 79
Series
TRITA-IIP, ISSN 1650-1888 ; 2017:9
National Category
Engineering and Technology
Research subject
Production Engineering
Identifiers
URN: urn:nbn:se:kth:diva-217360ISBN: 978-91-7729-536-5 (print)OAI: oai:DiVA.org:kth-217360DiVA, id: diva2:1155995
Public defence
2017-12-15, M311, Brinellvägen 68 KTH-Campus, Stockholm, 10:00 (English)
Supervisors
Note

QC 20171128

Available from: 2017-11-28 Created: 2017-11-10 Last updated: 2017-11-28Bibliographically approved
List of papers
1. Digitalization of Process Planning of Spot Welding in Body-in-white
Open this publication in new window or tab >>Digitalization of Process Planning of Spot Welding in Body-in-white
Show others...
2016 (English)In: Procedia CIRP, Elsevier, 2016, p. 618-623Conference paper, Published paper (Refereed)
Abstract [en]

Process planning of spot welding for body-in-white automobile structures involves several experimental (physical) welding trials to set the process parameters. These experimental trials are crucial in ensuring the quality and efficiency of the process. However, due to the iterative nature of the work, running several experiments is costly and time consuming prolonging the overall development cost and time significantly. To minimize the cost and time, replacing the physical tests by digital (virtual) tests is an established approach although not often applied for spot welding. However, for a long chain of development process with several iterative loops, this is not a trivial task considering the availability of information and continuity of the work flow. This paper reports the work and results of an industrial case study conducted on spot welding of a body-in-white car pillar in a Swedish auto manufacturer. The aim of the study is to investigate and propose the necessary conditions required to replace a physical test by virtual tests in terms of validity and expedited execution of the process. Information sharing, knowledge reuse and streamlining the work flow have found to be critical condition for valid and rapid virtual tests.

Place, publisher, year, edition, pages
Elsevier, 2016
Keyword
automotive, finite element simulation, numerical methods, Process planning, resistance spot welding, value stream mapping, Automobile bodies, Automobile manufacture, Finite element method, Iterative methods, Resistance welding, Testing, Virtual reality, Welding, Development process, Experimental trials, Finite element simulations, Industrial case study, Information sharing, Spot welding
National Category
Vehicle Engineering
Identifiers
urn:nbn:se:kth:diva-195470 (URN)10.1016/j.procir.2016.05.082 (DOI)000387666600104 ()2-s2.0-84986593228 (Scopus ID)
Conference
26th CIRP Design Conference, 2016, 15 June 2016 through 17 June 2016
Note

QC 20161110

Available from: 2016-11-10 Created: 2016-11-03 Last updated: 2017-11-13Bibliographically approved
2. Experimental measurements and numerical simulations of distortions of overlap laser-welded thin sheet steel beam structures
Open this publication in new window or tab >>Experimental measurements and numerical simulations of distortions of overlap laser-welded thin sheet steel beam structures
2017 (English)In: Welding in the World, ISSN 0043-2288, E-ISSN 1878-6669, Vol. 61, no 5, p. 927-934Article in journal (Refereed) Published
Abstract [en]

Distortions of mild steel structures caused by laser welding were analyzed. One thousand-millimeter U-beam structures were welded as overlap joints with different process parameters and thickness configurations. Final vertical and transverse distortions after cooling were measured along the U-beam. Significant factors, which affect distortions, were identified. Heat input per unit length, weld length, and sheet thickness showed a significant effect on welding distortions. Furthermore, the welding distortions were modeled using FE simulations. A simplified and computationally efficient simulation method was used. It describes the effect of shrinkage of the weld zone during cooling. The simulations show reasonable computation times and good agreement with experiments.

Place, publisher, year, edition, pages
SPRINGER HEIDELBERG, 2017
Keyword
Laser beam welding, Distortions, FE simulation, Volume shrinkage method, Mild steel
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:kth:diva-215469 (URN)10.1007/s40194-017-0496-z (DOI)000411060800006 ()2-s2.0-85027870009 (Scopus ID)
Note

QC 20171017

Available from: 2017-10-17 Created: 2017-10-17 Last updated: 2017-11-13Bibliographically approved
3. Experiments and efficient simulations of distortions of laser beam welded thin sheet closed beam steel structures
Open this publication in new window or tab >>Experiments and efficient simulations of distortions of laser beam welded thin sheet closed beam steel structures
(English)In: Article in journal (Refereed) Accepted
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-217610 (URN)
Note

QCR 20171115

Available from: 2017-11-15 Created: 2017-11-15 Last updated: 2017-11-28Bibliographically approved
4. Verification and evaluation of simulation methods of laser beam welding of thin sheet steel structures
Open this publication in new window or tab >>Verification and evaluation of simulation methods of laser beam welding of thin sheet steel structures
(English)In: Article in journal (Refereed) Submitted
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-217611 (URN)
Note

QCR 20171115

Available from: 2017-11-15 Created: 2017-11-15 Last updated: 2017-11-28Bibliographically approved

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