Corner Strengthening by Local Thickening and Ausforming Using Planar Compression in Hot Stamping of Ultra-High Strength Steel Parts

Hot-stamped products are widely used for the body-in-white of an automobile as they are lightweight and improve crashworthiness. A hot-stamping process using planar compression was developed to strengthen corners of ultra-high strength parts by local thickening and hardening. In this process, the corners are thickened by compressing the blank in the planar direction with the upper and lower dies while blocking the movement of both edges with stoppers in the latter stage of forming. Thickening of the corners largely heightens the strength of the formed parts. Not only the thickness but also the hardness of the corner was increased by large plastic deformation and die quenching. For a hot hat-shaped part, a 30% increase in thickness and a 530 HV20 hardness around the corners were attained. The bending rigidity and strength of the formed parts thickened by 30% in the corners increased by 25% and 20%, respectively. In addition, the improvements of the part shape accuracy and the sidewall quenchability were obtained.

Challenges Faced While Designing Body in White

Construction of Body in White (BiW) revolves around plenty of challenges. Ranging from BiW fixtures to curbing weight of Body in White sheet metal design. This paper discusses about all the design aspects in BiW manufacturing in automobile and confronting challenges that occurs. At present, lots of existing theories are being applied and efforts to improve the same are being made. This paper provides a path on how components can be developed and make necessary improvements. CAE (Computer Aided Engineering) tools have been used for FEA (Finite Element Analysis) and also an example of stress analysis of automotive chassis is given. An outcome depending on behaviour of loads acting on frame is drawn. The importance of hollow tubes, tubes of different- cross sections to counter weight and ease the designing of BiW frame have been proposed. This paper also provides insight on safety parameters with current construction of tubular frame chassis. Other solutions such as hybrid tubes, foam padding and plastic trim have been pointed out in this paper. Keywords: CAE, FEA, manufacturing, loads, tubes, cycle-time, cross-section.

Verification and validation of an automated robot inspection cell for automotive body-in-white: a use case for the VALU3S ECSEL project

Verification and validation (V&V) of systems, and system of systems, in an industrial context has never been as important as today. The recent developments in automated cyber-physical systems, digital twin environments, and Industry 4.0 applications require effective and comprehensive V&V mechanisms. Verification and Validation of Automated Systems' Safety and Security (VALU3S), a Horizon 2020 Electronic Components and Systems for European Leadership Joint Undertaking (ECSEL-JU) project started in May 2020, aims to create and evaluate a multi-domain V&V framework that facilitates evaluation of automated systems from component level to system level, with the aim of reducing the time and effort needed to evaluate these systems. VALU3S focuses on V&V for the requirements of safety, cybersecurity, and privacy (SCP). This paper mainly focuses on the elaboration of one of the 13 use cases of VALU3S to identify the SCP issues in an automated robot inspection cell that is being actively used for the quality control assessment of automotive body-in-white. The joint study here embarks on a collaborative approach that puts the V&V methods and workflows for the robotic arms safety trajectory planning and execution, fault injection techniques, cyber-physical security vulnerability assessment, anomaly detection, and SCP countermeasures required for remote control and inspection. The paper also presents cross-links with ECSEL-JU goals and the current advancements in the market and scientific and technological state-of-play.

Path planning of spot welding robot based on multi-objective grey wolf algorithm

The path planning of traditional spot welding mostly uses manual teaching method. Here, a new model of path planning is established from two aspects of welding length and welding time. Then a multi-objective grey wolf optimization algorithm with density estimation (DeMOGWO) is proposed to solve multi-object discrete problems. The algorithm improves the coding method and operation rules, and sets the density estimation mechanism in the environment update. By comparing with other five algorithms on the benchmark problem, the simulation results show that DeMOGWO is competitive which takes into account both diversity and convergence. Finally, the DeMOGWO algorithm is used to solve the model established of path planning. The Pareto solution obtained can be used to guide the welding sequence of body-in-white(BIW) workpieces.