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Proposed in this paper is a framework of virtual plant model for verification of PLC program by conducting the virtual plant modeling and simulation. The proposed virtual plant model consists of three types of objects: the virtual device model (object model), the intermediary transfer model (functional model) and PLC program (dynamic model). For the implementation of the proposed virtual plant model, this paper employs the I/O model which is based on Automata and Discrete Event System Specifications (DEVS) formalism. By applying an example of the automotive assembly line, nine errors in the PLC code are found and have been revised. With the proposed approach, it will be helpful to reduce the ramp up or down time of the automated manufacturing system. [ABSTRACT FROM AUTHOR]

This paper presents three projects of Faurecia in the domain of composite part forming and an evaluation of current forming simulation approaches regarding an application in the automotive industry. Via the latter the most performant group of currently available simulation approaches is identified. Their main drawback is however a high computational effort and further research should be done in order to accelerate them. Hereafter recommendations for an ideal forming simulation approach are identified by presenting three projects of Faurecia in the domain of composite part forming. [ABSTRACT FROM AUTHOR]

Hemming is a forming operation used in the automotive industry to join inner and outer components during the assembly of closures. These are typically opening parts of the body-in-white with additional requirements to their visual appearance. A suitable production concept of hemming operation which satisfies quality, capacity and cost requirements is determined during hemming planning activities. A digital tool to facilitate these activities and minimize the amount of trial and error iterations in try-out phase is presented in this paper. This tool can be used to define process plan, active tool surfaces and suitable process parameters for both die hemming and roll hemming operations. In case of early feasibility studies, when the die layout of the drawing operation is still not available, 3D part geometry is used directly to develop the concept of hemming process. Advanced validation studies, aimed at process optimization and controlling defects associated with hemming, can be based on complete simulation of all forming operations. Validation and analysis of developed concepts of hemming operation is done using the standard AutoForm-Incremental solver. Submesh strategy and special algorithm for contact description between inner and outer parts were implemented to ensure that accurate simulation results can be obtained within reasonable calculation time. Performance of the new software tool for hemming planning and accuracy of simulation results are demonstrated using several simple benchmarks and a real industrial part. It is shown that the new software tool can help to secure the efficient production launch by providing adequate support in try-out phase. [ABSTRACT FROM AUTHOR]

Press hardening is a well-established production process in the automotive industry today. The actual trend of this process technology points towards the manufacturing of parts with tailored properties. Since the knowledge of the mechanical properties of a structural part after forming and quenching is essential for the evaluation of for example the crash performance, an accurate as possible virtual assessment of the production process is more than ever necessary. In order to achieve this, the definition of reliable input parameters and boundary conditions for the thermo-mechanically coupled simulation of the process steps is required. One of the most important input parameters, especially regarding the final properties of the quenched material, is the contact heat transfer coefficient (IHTC). The CHTC depends on the effective pressure or the gap distance between part and tool. The CHTC at different contact pressures and gap distances is determined through inverse parameter identification. Furthermore a simulation strategy for the subsequent steps of the press hardening process as well as adequate modeling approaches for part and tools are discussed. For the prediction of the yield curves of the material after press hardening a phenomenological model is presented. This model requires the knowledge of the microstructure within the part. By post processing the nodal temperature history with a CCT diagram the quantitative distribution of the phase fractions martensite, bainite, ferrite and pearlite after press hardening is determined. The model itself is based on a Hockett-Sherby approach with the Hockett-Sherby parameters being defined in function of the phase fractions and a characteristic cooling rate. [ABSTRACT FROM AUTHOR]