Recent progress in simulation methods for the manufacturing industry has reduced the need for expensive test hardware. Using manufacturing simulation tools starting at the design stage helps to optimize product development and corresponding manufacturing systems. Whenever there is a need for an early design input in order to ensure quality and manufacturing costs - virtual manufacturing methods will be profitable.
For the case study E-Coat simulation, STAR-CCM+ provides an improved workflow from CAD-data and meshing to E-coat deposition as well as modeling of fill and drain behaviors in vehicle paint shops. Simulation results provide the design engineer with answers to questions such as ´is the E-Coat providing corrosion protection in all the cavities´? or ´is there a corrosion risk based on air bubbles or paint ponds´?
The combination of an implemented fast algorithm with the possibility of describing customer developed material properties through field functions allows for modeling of complex chemical material behavior.
An overview of future manufacturing simulation topics is also included in this presentation.