Abstract
AbstractManufacturing processes in sheet metal forming industry are subject to process-related variations, which can adversely influence the manufacturing costs and the quality of products. For example, during sheet metal forming of car body components, variations in material characteristics of the semi-finished product and in process parameters can lead to variations in the springback behavior of the sheet metal parts and therefore restrict the tolerances that can be realized with sufficient process reliability. In the assembly process, the springback variations of the individual sheet metal parts can also affect the dimensional accuracy of the joined sheet metal assembly and therefore the quality of the car body. In the course of digitizing the process chains in car body manufacturing, one of the objectives is to visualize such springback variations occurring after forming and joining processes of the individual sheet metal parts as well as of the sheet metal assembly at an early stage of development. On the one hand, this allows sheet metal parts and parameters with highest influence on the assembly to be identified and robustly designed, resulting in time and cost savings in hardware phase. On the other hand, tolerances for “less-important” parts of the assembly could be opened up, which may lead to additional cost and time reduction during die manufacturing. Against this background, the present paper provides an approach for modelling the manufacturing process chain of a forming and joining process considering variations in process parameters and material characteristics using finite-element-method and method of metamodeling. Here, metamodeling is used to predict the process behavior and thus reduce the required simulation effort. Based on the metamodels, Monte-Carlo simulation is carried out in order to perform variation and tolerance analysis.KeywordsSheet metal assemblyManufacturing simulationVariation
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