The Virtual Paint Shop

Important results from the project

Development of simulation algorithms and tools for the main paint and surface treatment processes used in vehicle manufacturing. - Paint droplet break-up in electro static painting. (WP1) - Film build-up of cavity wax. (WP2) - Fluid access, drainage and where appropriate film build-up in dip applications. (WP3) - Robot paths for paint robots by use of 3D-scanning. (WP4) - Oven curing. (WP5) - Location of process holes in the body structure. (WP6) - Thermal sprying processes. (WP7)

Expected long term effects

The project will support the ability to reduce the manufacturing process environmental impact by being able to optimize the process such that a reduced consumption of chemicals and energy can be achieved. Another objective with the project is to make the early manufacturing engineering work more efficient. By doing simulations prior to available hardware can cost for prototypes and unforeseen problem be avoided. The ability to predict the manufactured result will also give positive result on the manufacturing cost and the produced quality. This will in the long run strengthen the competitiveness of this specific industry.

Approach and implementation

Ten work packages have been identified by the project partners. The first seven of the work packages address one specific prioritized problem in or related to the virtual paint shop. The general approach in these sub projects is to develop and implement models in a general form and continuously compare simulations to experiments, initially on test cases of simple geometries that still retain the relevant physics, and later on full scale problems. Only when the full model compares well to experiments, model simplifications and simulation speed-up is initiated. In addition, there are three work packages of supporting character; experimental work, demonstrator integration and project management.