Reduced VARIation in the manufacturing processes enabling LIGHTweight welded structures (VariLight)
Purpose and goal
The purpose of VariLight is to enable weight reduction of welded structures in order to reduce the environmental impact, shorten leadtime and improve productivity. The achieved goals have been to: - Study and map sources of variation throughout the process - Increase knowledge of local weld geometry and residual stresses for more accurate life estimations - Develop recommendations for manufacturing processes and design procedures with greater precision and reduced variation - Enable increased use of weight-to-strength-effective material without increasing the risk of failures
Expected results and effects
The project delivered desired result according to the impact categories: Instrumental: Based on demonstrators, recommendations for lifetime estimation, LCA, residual stresses, improvement methods, measurements, cutting processes and crack initiation are developed. Model for variation hierarchy, information management and visualization created. Conceptual: 13 academic publications and theses Capacity building: Training, movies, a handbook and presentations Cultural: Changed approaches within the organizations Enduring connectivity: Strengthened network
Planned approach and implementation
The project had three research questions: 1: What is the current situation regarding variation in load estimation, analysis of residual stresses, cut edges, and fabrication? 2: How can the negative effect of the variation identified be mitigated? 3: How should initiatives to reduce variation be prioritized from a holistic point of view to gain the best overall effect? The research was conducted in collaboration between academia and industry in seven workpackages, where the 7th had an holistic view. The project had 30 project meetings via Skype and 10 meetings face to face.