E-coat Paint Process Simulation using Finite element analysis

Case Studies
The following case studies are meant to be representative of the many different types of investigative work that can be accomplished by Finite Element Analysis (FEA) with the Parametric Module. These include examples from rocker panel design optimization to visualization of the E-coat paint process in operation.

Several PC work stations were used to create and run simulations for the case studies, including a Dual Intel Xeon 3.06 GHz PC with 4.5 GB RAM and an Intel Pentium 4 3.06 GHz with 1.5 GB RAM.

The typical elapsed time per iteration was related as a function of the total number of elements and the number of Boundary Conditions. The range of time required for one iteration varies from < 20 seconds for the simpler models to as much as ~25 minutes for the larger ones.

Case Study A: Visualizing 3D Car Body Paint Distribution

The designer of an E-coat paint system wants to enhance its presentations of the E-coat machine and its different pieces of equipment. The designer also wants to visualize what the ware will look like once it exits the E-coat machine, fully painted.

Body passing through E-coat tank

Situation
Car manufacturer has a request to design and build a new E-coat paint facility.

The designer of the E-coat paint system wants to prepare visualization for the client that will perform a virtual E-coat paint process for a typical car body.

Model
A 3D 1/2 symmetry model of the car was created from a surface model of a typical car body. Only half of the car was simulated, because the other half has the same results due to the symmetry of both the E-coat paint system and the car itself.

Initial voltage profile	E-coat film thickness distribution @ 240 V

Results
At 200 volts the average E-coat film thickness was a little low (not pictured). A second simulation was run at 40 volts more, which yielded satisfactory results. The second simulation reveals that the E-coat film thicknesses were in an acceptable range and the applied voltage is typical for a new system start up.

Conclusion
The simulation tool provides the designer with a powerful sales tool to present the process of painting car bodies. The prospective owner of the E-coat system is given additional confidence that the start-up will be within the acceptable limits for both quality and cost.

Case Study A    |    Case Study B    |    Case Study C    |    Case Study D    |    Case Study E    |   Case Study F