Optimization of Manufacturing Process for Exterior Quality of Commercial Vehicle by Multi-physics Simulations
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ORIGINAL RESEARCH
Optimization of Manufacturing Process for Exterior Quality of Commercial Vehicle by Multi‑physics Simulations Wooju Lee1,2 · Hyunjoo Lee1 · Jiyae Bae1,2 · Dongchoul Kim1 Received: 22 January 2020 / Revised: 30 April 2020 / Accepted: 25 June 2020 © Korean Multi-Scale Mechanics (KMSM) 2020
Abstract The aesthetic aspect of automobiles continuously plays an important role in attracting consumer’s purchasing intention. In accordance with the needs of customers, automobile industries try to evaluate and amend a surface defect of their products. This research identifies manufacturing variables that have considerable correlation with surface defects in the exterior panel of large commercial vehicle and investigates the optimal condition of them to minimize the flaws. Multiple manufacturing processes that the exterior panel undergoes are modeled based on the multi-physics approach. From the computational analysis, the influences of the manufacturing variables on the surface defect are systematically analyzed to define effective parameters. An optimization regarding the influential variables is conducted and presents the optimized manufacturing processes for the high exterior quality of commercial vehicle. Keywords Commercial vehicle · Surface deflection · Finite element method · Optimization · Multi-physics approach
Introduction The exterior quality of commercial vehicle is recently one of the most important aspects for consumer so that a defect, even it is barely noticeable, on the exterior panel gives serious negative influence on marketing. The small deflection of the exterior panel is generated during the manufacturing process and it is difficult to be fixed since the current manufacturing process is composed of multiple processes such as assembly and painting. Small deflection can affect the performance of the device as well as material properties [1–3]. Particularly, it is possible to transfer the higher stresses from the interior to the edge of the panels [4]. To date, researchers have tried to investigate deformations during various manufacturing processes. Saxena et al. predicted the onset height of a cup that caused wrinkling during the stamping process utilizing Hill’s bifurcation criterion method and parametric study of process conditions [5]. Wang and Cao developed a model to predict a wrinkling * Dongchoul Kim [email protected] 1
Department of Mechanical Engineering, Sogang University, Seoul 04107, Republic of Korea
Research & Development Division, Hyundai Motor Group, Gyeonggi‑do 16082, Republic of Korea
2
in sheet metal forming process combining finite element method and analytical solution. They overcame an overprediction and sensitivity problem of finite element method with the model [6]. Makinouchi showed that finite element simulations could successfully predict various kinds of surface defects of automobiles, such as wrinkle or deflection in manufacturing processes [7]. Shen et al. performed a quantitative analysis to evaluate the surface deflection generated on automobi
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