Virtual PaintShop - Simulation of Electrocoating

Important results from the project

The project aimed to develop validated simulation methods and software for simulating electrodeposition and electroplating, with the goal of reducing the need for early prototypes and improving the product´s corrosion protection by identifying and addressing accessibility and drainage issues. The conclusion from the case studies is that simulations can be used to predict process outcomes, optimize process parameters, and detect areas with access and drainage problems. Overall, the project successfully met its objectives.

Expected long term effects

Several modeling approaches were explored to achieve a balance between simulation accuracy, computational performance, and user-friendliness. Comparisons with other simulation tools confirm that the results attain state-of-the-art levels in both accuracy and performance. The project´s outcomes will be implemented through bilateral collaborations with the partners. Thereafter, through additional investments, a module based on these results will be integrated into the IPS Virtual Paint platform.

Approach and implementation

Mathematical models and algorithms were developed with a strategy that involves continuous verification of simulation results through comparison with measurements. Verification initially took place at the laboratory level and was later expanded through case studies in production environments. The developed simulation technique underwent thorough validation in a total of 11 different case studies. Project participants have had access to early prototypes throughout the project, facilitating collaboration and information exchange among project partners.