The stone chip resistance performance of automotive coatings has attracted increasing attention in academic and industrial communities.Even though traditional gravelometer tests can be used to evaluate stone chip resi...The stone chip resistance performance of automotive coatings has attracted increasing attention in academic and industrial communities.Even though traditional gravelometer tests can be used to evaluate stone chip resistance of automotive coatings,such experiment-based methods suffer from poor repeatability and high cost.The main purpose of this work is to develop a CFD-DEM-wear coupling method to accurately and efficiently simulate stone chipbehaviorof automotive coatings inagravelometer test.Toachieve this end,an approach coupling an unresolved computational fluid dynamics(CFD)method and a discrete element method(DEM)are employed to account for interactions between fluids and large particles.In order to accurately describe large particles,a rigid connection particle method is proposed.In doing so,each actual non-spherical particle can be approximately described by rigidly connecting a group of non-overlapping spheres,and particle-fluid interactions are simulated based on each component sphere.An erosion wear model is used to calculate the impact damage of coatings based on particlecoating interactions.Single spherical particle tests are performed to demonstrate the feasibility of the proposed rigid connection particle method under various air pressure conditions.Then,the developed CFD-DEM-wear model is applied to reproduce the stone chip behavior of two standard tests,i.e.,DIN 55996-1 and SAE-J400-2002 tests.Numerical results are found to be in good agreement with experimental data,which demonstrates the capacity of our developed method in stone chip resistance evaluation.Finally,parametric studies are conducted to numerically investigate the influences of initial velocity and test panel orientation on impact damage of automotive coatings.展开更多
Automotive surface coating manufacturing is one of the most sophisticated and expensive steps in automotive assembly. This step involves generating multiple thin layers of polymeric coatings on the vehicle surface thr...Automotive surface coating manufacturing is one of the most sophisticated and expensive steps in automotive assembly. This step involves generating multiple thin layers of polymeric coatings on the vehicle surface through paint spray and curing in a multistage, dynamically changing environment. Traditionally, the quality control is solely post-process inspection based, and process operational adjustment is only experience based, thus the manufacturing may not be （highly） sustainable. In this article, a multiscale system modeling and analysis methodology is introduced for achieving a sustainable application of polymeric materials through paint spray and film curing in automotive surface coating manufacturing. By this methodology, the correlations among paint material, application processes and coating performance can be identified. The model-based analysis allows a comprehensive and deep study of the dynamic behaviors of the material, process, and product in a wide spectrum of length and time. Case studies illustrate the efficacy of the methodology for sustainable manufacturing.展开更多
In recent years, the waterborne free intermediate coating process has been widely used in the automotive industry. Because the baking times and coating thickness are decreased, the surface covering capability of the p...In recent years, the waterborne free intermediate coating process has been widely used in the automotive industry. Because the baking times and coating thickness are decreased, the surface covering capability of the painting process is reduced, which directly affects the appearance quality（ long-and short-wave values） of the body paint. Thus, there are correspondingly higher requirements for the white body surface profile prior to painting. The surface profile of the white body is mainly affected by the plate material, the surface profile, and the deformation process. So,the change rule for the surface profile during deformation of the steel plate is a key factor in coating appearance optimization. In this paper, we first analyze the typical deformation of the outer cover of a car body. Then ,we examine the change tendency of the surface profile of steel plates with respect to different deformation rates, specifically for a steel plate comprising a hot-dip galvanized bake-hardened steel sheet. Based on our analysis of the influence of the deformation on the coating appearance,we selected 3% ,5% ,and 8% deformation rates in this research. We found the roughness （Ra） value in the typical deformation range （3% -8% ） of the car body to exhibit a decreasing trend at first and then an increasing trend. The Ra value of the 8% deformation is not more than the original plate test value. When the Pc value of the original plate is in the lower range （ about 60）, it exhibits a slight increasing trend in the deformation process （3 % -8 % ）. And when the Pc value of the original plate is in the higher range （ about 120 ）, it exhibits no increasing trend in the deformation process （ 3% -8% ）. In contrast,the waviness （WCA） value in the car body＇s typical deformation range （3%-8%） shows a significant growth trend.展开更多
基金supported by the National Key R&D Program of China(No.2017YFE0117300)the Science and Technology Planning Project of Guangzhou(No.201804020065)the Innovation Group Project of Southern Marine Science and Engineering Guangdong Laboratory(Zhuhai)(No.311021013).
文摘The stone chip resistance performance of automotive coatings has attracted increasing attention in academic and industrial communities.Even though traditional gravelometer tests can be used to evaluate stone chip resistance of automotive coatings,such experiment-based methods suffer from poor repeatability and high cost.The main purpose of this work is to develop a CFD-DEM-wear coupling method to accurately and efficiently simulate stone chipbehaviorof automotive coatings inagravelometer test.Toachieve this end,an approach coupling an unresolved computational fluid dynamics(CFD)method and a discrete element method(DEM)are employed to account for interactions between fluids and large particles.In order to accurately describe large particles,a rigid connection particle method is proposed.In doing so,each actual non-spherical particle can be approximately described by rigidly connecting a group of non-overlapping spheres,and particle-fluid interactions are simulated based on each component sphere.An erosion wear model is used to calculate the impact damage of coatings based on particlecoating interactions.Single spherical particle tests are performed to demonstrate the feasibility of the proposed rigid connection particle method under various air pressure conditions.Then,the developed CFD-DEM-wear model is applied to reproduce the stone chip behavior of two standard tests,i.e.,DIN 55996-1 and SAE-J400-2002 tests.Numerical results are found to be in good agreement with experimental data,which demonstrates the capacity of our developed method in stone chip resistance evaluation.Finally,parametric studies are conducted to numerically investigate the influences of initial velocity and test panel orientation on impact damage of automotive coatings.
基金Supported in part by US NSF (CBET 0647113 and 0730383, CMMI 0700178, and DUE 0736739)the Institute of Manufacturing Research of Wayne State University.
文摘Automotive surface coating manufacturing is one of the most sophisticated and expensive steps in automotive assembly. This step involves generating multiple thin layers of polymeric coatings on the vehicle surface through paint spray and curing in a multistage, dynamically changing environment. Traditionally, the quality control is solely post-process inspection based, and process operational adjustment is only experience based, thus the manufacturing may not be （highly） sustainable. In this article, a multiscale system modeling and analysis methodology is introduced for achieving a sustainable application of polymeric materials through paint spray and film curing in automotive surface coating manufacturing. By this methodology, the correlations among paint material, application processes and coating performance can be identified. The model-based analysis allows a comprehensive and deep study of the dynamic behaviors of the material, process, and product in a wide spectrum of length and time. Case studies illustrate the efficacy of the methodology for sustainable manufacturing.
文摘In recent years, the waterborne free intermediate coating process has been widely used in the automotive industry. Because the baking times and coating thickness are decreased, the surface covering capability of the painting process is reduced, which directly affects the appearance quality（ long-and short-wave values） of the body paint. Thus, there are correspondingly higher requirements for the white body surface profile prior to painting. The surface profile of the white body is mainly affected by the plate material, the surface profile, and the deformation process. So,the change rule for the surface profile during deformation of the steel plate is a key factor in coating appearance optimization. In this paper, we first analyze the typical deformation of the outer cover of a car body. Then ,we examine the change tendency of the surface profile of steel plates with respect to different deformation rates, specifically for a steel plate comprising a hot-dip galvanized bake-hardened steel sheet. Based on our analysis of the influence of the deformation on the coating appearance,we selected 3% ,5% ,and 8% deformation rates in this research. We found the roughness （Ra） value in the typical deformation range （3% -8% ） of the car body to exhibit a decreasing trend at first and then an increasing trend. The Ra value of the 8% deformation is not more than the original plate test value. When the Pc value of the original plate is in the lower range （ about 60）, it exhibits a slight increasing trend in the deformation process （3 % -8 % ）. And when the Pc value of the original plate is in the higher range （ about 120 ）, it exhibits no increasing trend in the deformation process （ 3% -8% ）. In contrast,the waviness （WCA） value in the car body＇s typical deformation range （3%-8%） shows a significant growth trend.
