Process simulation

The ability to forecast characteristics of products and associated

manufacturing processes is increasing dramatically. Engineers can now study

and optimize multiple material and process scenarios early in the design

stage. Companies doing so are finding new opportunities for reduced lead

times, less risk of wrong investments, better optimised products and

processes etc.

The effect of different material and process parameters on product and

process characteristics can be simulated in special FEM program capable of

handling complicated characteristics and boundary conditions. It is

particulary interesting to be able to simulate behaviours at different

levels of detail and how they interact.

Virtual verification of a planned production process can reveal problems at

an early stage and allow corrections to be applied before tools, jigs etc.

have been manufactured. Collision between for example the workpiece and a

welding torch or adhesive dispensing equipment can be avoided.

Reachabillity, time seqeunce, adhesive consumption (if adhesive bonding),

are other areas that can be studied.

In other words can the process simulation reduce time-to-market by

visualizing and validating the process digitally - before the product design

is frozen, before committing resources and before purching or modifying

equipment and tooling. It is also important to mention that once validated,

engineers can use the product and process models for training, maintenance

and documentation.

Here follows illustrations in form of three examples of process simulation.

The examples illustrate adhesive dispensing, welding and sealant dispensing.

> The three pictures shows;

No.1). Adhesive dispensing on the windscreen (on a "moving pictures" you

could see the cars coming in, the dispensing of adhesive, mounting of the

screen to the carbody etc.). Here you can check up that there not is any

risk for collision between the adhesive pistol and jigs, reachabillity etc.

No.2). Welding of a larger detail, in form of a forklift part. Here you can

check up the inloading sequence, spatter, the arc behaviour etc.

No.3). Dispensing of sealants to a car front-hood. Here you could check the

time sequence and consuming of sealants etc.

Not. Reference to the text above and all three pictures; Tehdasmallit Oy,

Deneb Robotics and IVF. In picture no.2 also BT Forklifts AB.