Synchronous Engineering (se) In The Car White Body For The Application Of Quality Control

From initial concept review to overall vehicle design, from body-in-white parameter design, trial manufacturing, testing, to small scale production and mass production, new vehicle development is typically a very long process. Parts manufacturability, welding order, welding technique, and quantity control documents should be considered carefully at design stage. Engineering design and data from trial manufacturing determine vehicle development time and quality. Therefore,3D data and quality control documents are very critical at this stage. Some production preparation work can also start at design stage using simultaneous engineering(SE), such as review and validation of key parts manufacturability, data validity and manufacturability based on production experience, design principles, and computer simulation.Among stamping, welding, painting, and assembly, stamping and welding are most important to body-in-white quality. This thesis investigated the application of SE technique to stamping and welding of body-in-white.We first performed simulation analysis of the exterior plate of the side wall and the interior plate of the rear door using Autoform to analyze parts formability, potential defects, defect locations and causes, and suggests modifications based on experience. We then analyzed trial manufacturing of body-in-white using simulation results and SE principles. The trial manufacturing results suggest that SE is very valuable to guide design modifications of vehicle structure and stamping techniques. We also followed the trial manufacturing process which demonstrates that stamping SE can help to reduce stamping defects to minimal.We then analyzed the application of SE technique to welding and developed welding principles and proposals. Body-in-white consists of about400stamping parts. The only approach to assuring body-in-white size, strength, and precision is to control welding quality. Welding quality is determined by stamping parts weldability. Data weldability is therefore another key consideration at design stage. Data weldablity should be validated based on experience, using welding principles, and through thorough review of welding angles by experienced welding engineers. Welding engineers can also use welding simulation, logistic simulation, and digital factory software to validate parts manufacturability and suggest improvements to welding technique. This thesis studied and summarized data weldability principles and validated their importance to welding and body-in-white quality.To validate the overall effect of the SE technique, as the third study, we then analyzed trial manufacturing of body-in-white. The body-in-white was built using trial manufacturing engineering materials, stamping and welding. Results of this study are consistent with the other two studies and conclude that the SE technique is very effective to the development of body-in-white.To summarized, our study results suggest that the combination of vehicle design and SE activities can significantly reduce design modifications, shorten production preparation, reduce production costs, and improve vehicle quality.