Browse Publications Technical Papers 2020-01-0898
2020-04-14

A study of a fast and precise thickness simulation of an industrial e-coating process 2020-01-0898

Corrosion protection by employing the process of electro coating (e-coating) is one of the key processes in automotive industry. Here, achieving an optimal paint layer distribution on the bodies is typically an expensive and time-consuming process. Hence, there is a high demand for precise and fast simulation tools to optimize this process, which eventually can lead to sever energy savings and cost reduction. However, obtaining a fast simulation while maintaining its accuracy is a challenging topic. In this paper, key factors for obtaining a fast and precise thickness simulation in e-coating are thoroughly discussed. To that end, dedicated pre-processing based on lab experiments is included. These experiments are key to obtain the correct paint parameters and serve as a baseline for an accurate simulation tool. Based on these paint parameters, a precise description of the simulation of industrial e-coating environments is included. The proposed simulation software is applied to an industrial real world problem using a state-of-the art car body. Correlation with physical measurements are presented, as well as how the software helped to optimize this industrial e-coating process.

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