Joining in Car Body Engineering 2012

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Battistina Castelli
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1 Joining in Car Body Engineering 2012 Optimization of dimensional quality in adhesivebonded joints along manufacturing process chain Antonio Annicchiarico Manuel Lai Rosanna Brun 20 Novembre, 2010 Fiat Research Center: Overview Centro Ricerche Fiat started its activities in 1978 CRF is the Fiat SpA reference hub for innovation and research CRF has approximately 1000 employees CRF has a global network with over 400 Universities and Research Centers CRF has registered over 3200 patents worldwide with over 450 pending applications 2

activities in 1978 CRF is the Fiat SpA reference hub for innovation and research CRF has approximately 1000 employees CRF has a

2 Agenda 1. Overview 2. Mechanical characterization of adhesives during thermal cycles 3. Methodology development of thermo-mechanical coupled analysis 4. Project optimization through thermo-mechanical analysis 5. Conclusions and outlook Overview

3 Methodology development Mechanical characterization of adhesives during thermal cycles within the manufacturing process chain (different adhesives) Methodology development of thermomechanical coupled analysis Test case, FIAT Bravo hood (first application) Methodology validation on Giulietta hood Methodology development for door Application on new Panda Methodology development for aluminum Application on new models (FIAT, ALFA, MASERATI) Hood manufacturing Hemming structural adhesive between inner and outer panels Structural mono-component adhesive epoxy based with precuring cycle (perimetral) Anti-flutter adhesive monocomponent vinyl-based (central) Anti-flutter adhesive between inner and outer panels

Application on new Panda Methodology development for aluminum Application on new models (FIAT, ALFA, MASERATI) Hood manufacturing Hemming structural adhesive between inner and outer

4 Methodology in brief Mechanical characterization of new adhesives LSS Output from characterization *MATERIAL inside the Abaqus model Hood process feasibility Hood FE Model Geometry changes and process optimizations Thermo-mechanical coupled analysis The goal is to assess smart methodologies able to virtually achieve high standards for dimensional quality of hang on parts at the end of the painting cycle Mechanical characterization of adhesives during thermal cycles

coupled analysis The goal is to assess smart methodologies able to virtually achieve high standards for dimensional

5 Mechanical characterization of adhesive, pre-curing thermal cycle Pre-curing tool design An optimized design of pre-curing tools guarantees geometric standard requirements for specimens realization: steel layers alignment and overlapping height between steel layers. Pre-curing induction tool design The optimization of the induction tool design leads to a robust process. Pre-curing station set-up With an optimized pre-curing station it s possible to realize standard specimens: with stable geometry; with a robust process. Mechanical characterization of adhesive, LSS test Curing thermal LSS test: the specimen is tested with a tensile test machine placed inside a climate chamber tensile test during warming, maintenance and cooling phases tensile test velocity, 12mm/min Thermal LSS test after curing : tensile test on specimen tensile test velocity, 12mm/min

Pre-curing station set-up With an optimized pre-curing station it s possible to realize standard specimens: with stable geometry; with a robust process.

6 Mechanical characterization of adhesives Mechanical characterization of different structural adhesive Mechanical characterization of SID adhesive (blue columns) Methodology development of thermo-mechanical coupled analysis

Mechanical characterization of SID adhesive (blue

7 Methodology development of thermomechanical analysis Thermal cycle on hang-on parts during manufacturing process chain: adhesive pre-curing paint oven curing Adhesive pre-curing Paint oven Hang-on parts repositioning: 1. on pre-curing tool 2. BIW mounted Dimensional measurement on vehicle position: 3. before adhesive pre-curing 4. after adhesive pre-curing 5. after paint oven Thermo-mechanical process simulation is able to: predict dimensional defects on hang-on parts; control dimensional quality of hang-on parts during the manufacturing process chain; optimize dimensional quality in adhesive-bonded joints. Thermo-mechanical analysis results

before adhesive pre-curing 4. after adhesive pre-curing 5.

8 Achieved results Design optimization 1 Selection among alternative hood inner structures Process optimization Selection of hot resistant adhesives Optimal use of indirect spot-welding Optimization of fixtures for cataphoresis cycle Inner structure with isotropic stiffness Giulietta hood (normal production) Giulietta hood (with isotropic structure) Good dimensional quality Thermo-mechanical process simulation supports in advance designers with design guidelines for hood, in this case, inner structure with isotropic stiffness not improves dimensional quality at the end of manufacturing process chain (after paint oven). Adhesive pre-curing Paint oven Dimensional measurement on vehicle position

structure) Good dimensional quality Thermo-mechanical process simulation supports in advance designers with design guidelines for hood, in this case, inner structure with

9 Spot-welding evaluation Optimization of spot-welding number and position After optimization Good dimensional quality Starting point In this case, optimization of number and position of spot-welding improves dimensional quality at the end of manufacturing process chain (after paint oven). Dimensional measurement on vehicle position Influence of support fixture for paint oven cycle Optimization of support fixture C-tool Good dimensional quality H-tool In this case, a new concept of support fixture for paint oven cycle improves dimensional quality at the end of manufacturing process chain (after paint oven). Dimensional measurement on vehicle position

Dimensional measurement on vehicle position Influence of support fixture for paint oven cycle Optimization of support fixture C-tool Good dimensional quality

10 Conclusions and outlook Conclusions and outlook At Fiat, since Alfa Giulietta model, dimensional quality of hang on parts is validated with a virtual methodology which allow to accurately predict dimensional defects of hang on parts The methodology gives upstream indications on the causes of dimensional defects in order to optimize the process and guarantee a faster achievement of quality target during industrialization It s possible to try new material/process solutions, e.g. even non-available adhesives, to address specific innovation projects

indications on the causes of dimensional defects in order to optimize the process and guarantee a faster achievement of quality target

11 Thank you for attention

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