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• W2619744 abstract "At Voestalpine Polynorm, hemming is used as an assembly method for closures (i.e.doors, hoods, tailgates and trunklids) in automotive bodies. Hemming is a process bywhich a metal sheet edge of an outer part is bent around an inner part.Robot roller hemming is a relatively new process. The process will be applied more andmore in the future due to market demands and process development. Too littlefundamental process knowhow is available. Achieving and maintaining the right productquality is therefore a trial-and-error process.Finite element analysis of the robot roller hemming process helps reducing this try-outphase. Goals are to create a more stable process and achieving the right product quality.The main targets are to create process setting guidelines which control the dimensionaland surface quality and reduce the overall process time.The simulations are performed with the finite element package Abaqus®. Thedevelopment of a 3D robot roller hemming simulation model is described in this report.The work presented in this report concentrates mainly on predicting the reduction in sizeof the outer part, called roll-in. The dimensions of the outer part have to be compensatedfor this roll-in, to obtain a finished product with the right dimensions.Started is with a simple 2D simulation model which can simulate the die and tabletophemming process. The use of implicit and explicit solution methods is investigated. Bothsolution methods can be applied in (quasi-static) hemming simulations.An element-type comparison is performed with a small 3D tabletop model. In this implicitsimulation model both solid and shell elements are used in the simulations. This way anaccurate and economical element is chosen for the 3D robot roller hemming model. Thecontinuum shell element is the most suitable element-type for large 3D robot rollerhemming models. This element-type showed a realistic roll-in behaviour (roll-in afterprehemming and this amount of roll-in was reduced during final hemming) during thesimulation, with the smallest amount of simulation time. The differences between shelland solid elements were smaller after prehemming than after final hemming.A parameter study of the prehemming step is performed on straight flat-surface partsbased on a ‘Design of Experiments’. Parameters which have a big influence on the roll-inof the process are identified with this set of simulations. After this, a response surfacemodel is created, from the roll-in response of the simulation model on the two mostimportant process parameters. This can be used by process engineers and robotprogrammers to create a stable process window by choosing the optimal process settingranges.Furthermore, guidelines are given to prevent the forming of wave patterns along theflange which disturb the quality of finished products." @default.
• W2619744 created "2016-06-24" @default.
• W2619744 creator A5084484366 @default.
• W2619744 date "2006-01-01" @default.
• W2619744 modified "2023-09-27" @default.
• W2619744 title "Simulation of the Robot Roller Hemming process" @default.
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