Digitalization of Process planning of joining

Purpose and goal

Process planning of joining processes is today carried out in a number of steps from specification of joining methods during product design over early process planning where process and process windows are selected to final planning of robot and machine control. These steps are today made based on physical trials. The aim of the project is to analyse proces planning for a demonstrator and formulate digital alternatives to today´s methods. This was done for a spot welded A-pillar in a body-in-white. A Significant potential exist to save lead time if two types of digital tools are available.

Results and expected effects

The project suggests that a data base is developed which contains process data for all previously tested combinations of materials and thicknesses. This shall be easy to use for designers and process planners. As a compliment FE simulation tools are developed and verified which can simulate process windows. This is available to advanced process planners and can replace physical tests. The access to these tools means that the lead time per development cycle of a new BiW can be shortend by some 2 months.

Approach and implementation

The process flow for development of a new BiW has been analysed with respect to design and process planning of joints in an A-pillar. The process flow was studied today based on current practice to use physical tests for process windows. Suggestions have been made for a new process flow where two digital tools are available. The tools have been described and reduction of lead times have been estimated.