Beitrag zur Identifizierung geometriebeeinflussender Stellgrößen im Karosseriebau

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The present work focuses on developing a software-supported assistance system for the series start-up process, aimed at compensating for process-related dimensional deviations in car body assemblies. This system is based on a parametric process chain simulation that spans from forming to hemming. By efficiently planning the simulative test series, a data-reduced prognosis model can be generated with minimal computational effort. This approach allows for the calculation of the effects of varying defined process parameters (such as blank holder forces and pin/clamp variations) on the dimensional accuracy of the final assembly across different process steps, with the results visualized in relation to the finite element mesh. The functionality of the assistance system is validated using a three-part test assembly, where 31 process parameters are systematically varied along the simulation process chain. This comprehensive method enables targeted adjustments to enhance the precision of car body assemblies during production, ultimately contributing to improved manufacturing efficiency and quality control.