VIRTUAL VALIDATION OF FUNCTIONAL AUTOMOTIVE DOOR ASSEMBLY PROPERTIES BY MEANS OF SUPERPOSED CAT AND FEM ANALYSIS

Year: 2015
Editor: Christian Weber, Stephan Husung, Marco Cantamessa, Gaetano Cascini, Dorian Marjanovic, Srinivasan Venkataraman
Author: Ehlert, Matthias; Heling, Björn; Wartzack, Sandro
Series: ICED
Institution: 1: BMW AG, Germany; 2: Friedrich-Alexander Universitaet Erlangen-Nuernberg, Germany
Section: Design Theory and Research Methodology, Design Processes
Page(s): 045-054
ISBN: 978-1-904670-65-0
ISSN: 2220-4334

Abstract

As with all industrially manufactured goods, it is generally necessary to ensure costumer requirements are met. Therefore, it is important to ensure that functional as well as optical specifications of a product are fulfilled for large quantities in series production. The following piece of work demonstrates the effect that the elasticity of an assembly has on specific functional criteria in order to meet the aim of a robust design. For this purpose an automotive door assembly is examined, where tightness is one of the most relevant attributes from the customer s perspective. In the present case, the effect of the elastic sealing system on the development of the limiting positions of the observed assembly that result from a corresponding tolerance analysis will be examined in greater detail which, in turn, has an impact on tightness. The term  limiting position generally describes the largest deviation from the nominal dimension that can occur with a high level of statistical probability. To that end, a simulation-based integrated process is introduced that covers CAT as well as FEM methods and in this way respects the elasticity of the system with its corresponding deformation.

Keywords: Computer Aided Design (CAD), Robust Design, Virtual Engineering (VE), Computer Aided Tolerancing (Cat)

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