Optimization of E-Coating Simulations in Automotive Painting Processes

Horvat, Lovro (2014) Optimization of E-Coating Simulations in Automotive Painting Processes. = Master's thesis (Bologna) , Sveučilište u Zagrebu, Fakultet strojarstva i brodogradnje, UNSPECIFIED. Mentor: Tonković, Zdenko.

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Abstract (Croatian)

The content of this thesis is the simulation of the e-coating process (cathodic electrocoating process) used in the automotive industry, in which the first paint layer that provides the main corrosion protection, is applied. The main aim of the simulation is to find out critical areas, where a minimum layer thickness will not be reached and give the necessary information earlier in the product development process, which leads to reduction of tryouts costs. The numerical simulations were performed by software THESEUS-FE E-Coating Module, which is based on the finite element method. Firstly, a detailed coating thickness measurement was performed to determine the coating distribution on a car body. Thereafter, on the basis of the car body CAD data and e-coating bath measurements, a finite element model (FE-model) of the car body in the bath was built. In order to reconstruct the measured coating thicknesses as good as possible, different simulation models and methods were investigated. The influences of holes and positioning of hood and doors on the process were also investigated. Furthermore, different voltage programs were considered in order to classify the influence of the voltage program and anodes positioning on the process in general. Also, the areas in the car body cavities without full paint coverage, which are of special interest for planning process, were identified. In order to avoid this, some additional holes on the car body were inserted, and thereafter the comparison of the simulation results and a real experiment should be performed. Moreover, in order to calibrate the lacquer parameters, experiments with a test-box, which is suitable for the throwing power measurement, were performed and thereafter simulated. Unfortunately, the calibration through the text-box was not very useful due to different process conditions between the test-box experiments and the e-coating process performed in a real paint shop. However, a detailed sensitivity analysis of different simulation parameters was also performed by means of test-box, in order to determinate the influence of certain parameters on the process.

Item Type: Thesis (Master's thesis (Bologna))
Uncontrolled Keywords: e-coating; cathodic electrocoating; simulation; finite element method
Date Deposited: 22 Sep 2014 18:00
Last Modified: 16 Oct 2015 12:46
URI: http://repozitorij.fsb.hr/id/eprint/2776

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