The Optimized Design For ED Holes Based On ECoatMaster

With the rapid development of auto industry,companies have gradually perfected development process,Simultaneous Engineering arises at the right moment.Simultaneous Engineering is to design manufacturing process during body designing,avoid design alternation,help cut down costs,shorten the period of development.ED effect is an important target of quality of BIW,which is also one main task of Simultaneous Engineering.Engineers used to analyze ED process by experience.However,there always were mistakes due to analyzing subjectively by experience.ECoat Master software is a professional software for ED simulation.It based on finite element simulation technique,can simulate the process of ED.Because of the results of simulation,it can evaluate the ED effect of BIW,optimize and prove the possibility of process plans.ECoat Master have advantages like high precision and easy operation.ECoat Master is widely applied by VW,Audi,GM,Benz and other auto companies and it has been proved to be appropriate for ED process planning in auto industry.This article based on ECoat Master,calculates data of body in white and checks areas with ED infects.Then give suggestions of improvement.After that,with anatomy of prototype vehicles,check whether the results could match measuring data,make sure the design can reach the goal of ED process.This article will mainly discuss in several aspects:firstly,benchmarking.Collect parameters of process and parameters of equipment.In supplier's laboratory,measure the parameter of coating,collect the data of thickness varying with voltage and speed of revolution.Set up database of coat.Put them into ECoat Master for analyzing.Build up the model of ED booth and path.Turn the data of producing vehicle into STL form.Put these data into ECoat Master.After automatically meshing,it comes to calculation,then compared the anatomical results with calculated results.Confirm the feasibility.Considering the deviation of software and calculation,we need software engineers to do amendment and improvement,update paint data and make sure that simulation results fit to actual situation.Secondly,Simultaneous Engineering.Refer to ?ED coat designing specification of car body?,evaluate probability of ED effect mainly about throwing power,venting ability and draining ability.Find out appropriate holes on different areas of body.Suggest adding ED holes and discuss modification plans with designers.Make sure that it can fulfill the requirement of intensity,rigidity,NVH and sealing.As soon as having the data for CAE,use ECoat Master to calculate.Thirdly,compare with the simulated result,offer optimized advices on adding ED holes and modification of structure.Feed back ECR and follow the schedule of optimized plans.Make sure the data has been corrected before it's frozen.Finally,ED anatomy of prototype car.After anatomy,we measure the ED thickness and compare the data with calculated results,then confirm the validity of optimized scheme.