DE102021130577A1 - Method for determining a manufacturing-related deformation of a shell component of a joined component composite - Google Patents

Abstract

The invention relates to a method for determining a production-related deformation (1) of a shell component (2) of a joined composite component (3) of a motor vehicle, in which the production-related deformation (1) of a virtual target geometry (8) is determined by means of a structural mechanical simulation (7). , which is an image (11) of a component geometry (6) which the shell component (2) has in the joined component composite (3), depending on at least one result variable (9) of a forming process of a production of the shell component (2) and is determined separately from the structural-mechanical simulation (7) that can be carried out forming simulation (10) of the shell part (2).

Description

The invention relates to a method for determining a heart position-related deformation of a shell component of a joined composite component of a motor vehicle.

A structural mechanical simulation, for example a finite element simulation, is known from the general state of the art, in which a deformation of a component can be calculated as a function of an, in particular mechanical, loading of the component. As a result, the deformation of the component can be predicted virtually using the structural-mechanical simulation. In addition, a manufacturing process for manufacturing the component can be mapped by means of a simulation. Such a simulation can include forming and/or joining.

It is the object of the invention to create a method for determining a manufacturing-related deformation of a shell component of a joined component composite of a motor vehicle, in which the manufacturing-related deformation can be determined with particularly little effort.

According to the invention, this object is achieved by a method for determining a production-related deformation of a shell component of a joined composite component of a motor vehicle with the features of patent claim 1 . Advantageous configurations of the invention are the subject matter of the dependent patent claims and the description.

The invention relates to a method for determining a production-related deformation of a shell component of a joined composite component of a motor vehicle. The motor vehicle is preferably designed as a motor vehicle, in particular as a passenger car, utility vehicle or truck, or as a passenger bus or motorcycle.

The shell component can be understood in particular as a component or an assembly of a shell of the motor vehicle. The body shell can be designed as a particularly self-supporting body of the motor vehicle. Preferably, the bodyshell includes the bodyshell in its fully manufactured state. In its fully manufactured state, the motor vehicle preferably includes the shell component or shell.

In its fully manufactured state, the joined component composite includes the shell component. In addition, the joined component assembly comprises a component which is formed separately from the shell component and which is connected to the shell component in the fully manufactured state of the joined component assembly. In this case, the raw component and the component are joined together, that is to say connected to one another by means of joining, for example by means of flanging. The joined composite component can be understood in particular as an assembly. In its fully manufactured state, the assembly comprises the body shell and the structural element.

Thus, producing the composite component or the assembly includes connecting, in particular joining, the shell component and the component.

The component can be designed as a second shell component that is formed separately from the shell component. This means that the second shell component can be a component or an assembly of the shell.

The bodyshell of the motor vehicle preferably includes the joined component composite in its fully manufactured state. Alternatively, the assembled component assembly can be designed as the shell. In its fully manufactured state, the motor vehicle preferably comprises the joined component composite.

The production-related deformation of the shell component can be understood in particular as a deformation which the shell component undergoes during its manufacture or for its manufacture and/or during or for the manufacture of the joined component composite. This means that the shell component is deformed during the production of the shell component or the production of the joined component composite.

For example, after it has been produced, the shell component can have a shape that is referred to in particular as a shell component geometry. For example, the raw component can be produced from a blank during its production or can be formed from the blank. Thus, the production-related deformation can include at least one deformation which the blank undergoes during the forming to the raw component geometry. The blank can be understood in particular as a semi-finished product.

For example, during the production of the joined component composite, the raw component is deformed during the joining or as a result of a joining process, for example a flanging process. This means that the shell component can have the shell component geometry before the joining and after the joining in the joined component composite a part geometry is referred to in particular as a joined component geometry May have shape, wherein the joined component geometry is different from the raw component geometry. The production-related deformation can thus include the deformation of the shell component during the joining or during the joining process.

For example, the bodyshell and/or the second bodyshell are formed as sheet metal or body sheet metal. For example, the bodyshell is designed as the outer skin of the bodyshell or the motor vehicle and the component is designed as a structural component of the bodyshell or the motor vehicle. Alternatively, the bodyshell can be designed as the structural component of the bodyshell or the motor vehicle and the component can be designed as the outer skin of the bodyshell or the motor vehicle.

For example, the bodyshell is designed as an inner panel of the bodyshell. In particular, when the shell is designed as the inner panel, the second shell can be designed as the outer panel of the shell. For example, the second bodyshell is designed as an inner panel of the bodyshell. In particular when the second shell component is designed as the inner panel, the shell component can be designed as the outer panel of the shell.

The body shell is preferably designed as a front flap of the body shell or body. The front flap can in particular be referred to as a hood.

In order to be able to determine the production-related deformation of the shell component of the joined component composite with particularly little effort, it is provided according to the invention that, by means of a structural mechanical simulation, the production-related deformation of a virtual target geometry, which is an image of the joined component geometry, which the shell component has in the joined component composite , is determined or calculated as a function of at least one result variable of a forming process, in particular at least one manufacturing step, of the production of the shell component that maps and can be carried out separately from the structural-mechanical simulation. In other words, in the structural-mechanical simulation, the production-related deformation of the raw component of the joined component composite is determined or calculated using the virtual target geometry depending on the result variable of the forming simulation. In other words, the virtual target geometry and the result variable of the forming simulation is a respective input variable of the structural-mechanical simulation or for the structural-mechanical simulation and the production-related deformation of the raw component of the joined component composite or the virtual target geometry is an output variable that differs from the respective input variable the structural mechanical simulation.

This means that the structural-mechanical simulation is intended to determine or calculate the deformation caused by production. The production-related deformation of the virtual target geometry is calculated or simulated, that is, the virtual target geometry is virtually deformed in the structural mechanical simulation. This can in particular be understood to mean that the production-related deformation of the virtual target geometry is predicted by means of the structural-mechanical simulation.

A numerical method, referred to in particular as a numerical method, can be used in the structural-mechanical simulation to determine or calculate the production-related deformation. The structural-mechanical simulation can thus be referred to in particular as a numerical, structural-mechanical simulation. For example, the numerical method is the finite element method (FEM). This means that the production-related deformation of the virtual target geometry can be calculated or approximated using the finite element method or using the finite element method.

The fact that the virtual target geometry is an image of the joined component geometry can in particular be understood to mean that the virtual target geometry is a virtual image or a virtual image of the joined component geometry. This means that the virtual target geometry represents or characterizes the joined component geometry of the shell component.

The virtual target geometry preferably includes data referred to as information, which characterize the component geometry. For example, the data includes a large number of data points, with each data point being assigned spatial coordinates which each depict or characterize a point in the component geometry.

For example, the virtual target geometry can be displayed as an image by means of an optical output device, which shows or depicts the component geometry.

The fact that the shell component has the joined component geometry in the joined component composite or the assembly can be understood in particular to mean that the joined component geometry includes a change in geometry of the shell component caused by the joining process for joining the component composite. In this case, the change in geometry can be understood in particular as a change in the shape of the shell component, starting from the shell component geometry towards the joined component geometry. The virtual target geometry thus includes the change in geometry of the shell component caused by the joining process for joining the composite component.

The virtual target geometry can be understood in particular as a CAD geometry of the joined component geometry of the shell component. Alternatively, the virtual target geometry can be understood to mean, in particular, a virtual, networked geometry. In this case, the virtual target geometry configured as a networked geometry can be created from the CAD geometry or as a function of the CAD geometry. In particular, this can be referred to as meshing the CAD geometry. The networked geometry can in particular be referred to as a mesh. The virtual target geometry can thus be a discrete mapping or approximation of the CAD geometry and thus of the joined component geometry of the shell component.

“CAD” can be understood in particular as “computer-aided design”. The CAD geometry can be understood in particular as a virtual geometry that depicts or characterizes the component geometry and can be created, in particular constructed, or created, in particular constructed, virtually using a CAD system.

The forming process can in particular be understood to mean the forming of the blank into the raw component. The forming simulation is a simulation that differs from the structural-mechanical simulation, which virtually maps the forming process at least partially, in particular completely. This means that during the forming simulation, the blank is subjected to virtual forming forces, which cause the blank to be formed into the raw component. In the forming process, the blank is formed into the raw component by means of at least one forming tool. The forming tool can thus bring about the forming forces. In this way, the impact of the forming forces on the blank can be reproduced or mapped during the forming simulation.

The forming simulation can be a further structural-mechanical simulation that is different from the structural-mechanical simulation or can include the further structural-mechanical simulation that is different from the structural-mechanical simulation.

The result variable of the forming simulation can be understood in particular as a simulation result of the forming simulation. The result variable or the simulation result is therefore an output variable of the forming simulation, which is determined, in particular calculated, is or can be determined, in particular can be calculated, during the forming simulation.

The dimensional accuracy of the formed or manufactured shell component can be predicted or ensured by the forming simulation. For example, the simulation result can include a deviation of an actual geometry of the formed shell component determined or calculated by means of the forming simulation and a target geometry of the formed shell component. In particular when this deviation is particularly small, for example negligible, the dimensional accuracy of the formed raw component can be ensured by means of the forming simulation.

The invention is based in particular on the following findings and considerations: In order to be able to particularly increase the quality of the joined component composite, it is conceivable to use simulation to predict and thereby secure the joining process, which is referred to in particular as the assembly process, in which the component composite or the assembly is joined. It is conceivable that such a simulation includes a joining simulation, in particular a flanging simulation. In the joining simulation, the joining process, in particular the flanging process, can be modeled and calculated. This means that during the joining simulation, the manufacturing-related deformation of the shell component or the composite component can be calculated during the joining process or through the joining process. A software tool, in particular a commercial one, can be used for this purpose. Thus, in the joining simulation, the joining, in particular the flanging, is virtually mapped or predicted.

Thus, the following simulation process chain would be conceivable for determining the production-related deformation: First, the forming of the blank and thus the formed raw component could be simulated or calculated by means of the forming simulation. Subsequently, the raw component virtually formed by means of the forming simulation could be used as an input variable for the joining simulation, in particular flanging simulation, ver be turned. For example, a simulation result of the joining simulation includes deformations or mechanical stresses of the joined shell component caused by the joining or the joining process. Then, by means of a further simulation, referred to in particular as an assembly simulation, a jump of the joined component composite or the shell component in the joined component composite could be simulated. This means that a virtual model of the composite component can be constructed, with the virtual model including the raw component. The simulation result of the joining simulation determined during the joining simulation, in particular the deformation and/or the mechanical stress, can be specified as an initial condition and/or as a boundary condition for the assembly simulation, with the jump being determined or calculated depending on the simulation result of the joining simulation.

Springback can be understood in particular as springing back. The crack can thus be a deformation or a change in geometry, which can occur during the joining process when a joining tool used to bring about the joining is removed from the composite component or the shell component after the joining. For example, during joining or by means of the joining tool, a mechanical stress can be induced in the raw component, which leads to the springing up or springback during or after the joining process. Thus, the jump or the springback can be understood in particular as a production-related deformation.

A total computing time of this conceivable simulation process chain can be particularly high. The simulation process chain can therefore be particularly complex. This can be the case in particular because the joining simulation, in particular the flanging simulation, can have a particularly high computing time and can therefore be particularly complex. In addition, modeling the joining process, in particular the flanging process, can be particularly complex, in particular particularly time-consuming.

In contrast, the production-related deformation can be determined or calculated with particularly little effort using the method according to the invention. This is the case in particular because the joining simulation, in particular the flanging simulation, can be omitted in the method according to the invention and is therefore not carried out. Instead of the joining simulation, the structural-mechanical simulation is carried out in the method according to the invention. This means that the result variable or the simulation result of the forming simulation is taken into account or mapped in the structural-mechanical simulation and thus flows into the structural-mechanical simulation as an input variable.

A simulation result of the joining simulation, for example mechanical stresses that can be induced in the raw component during the joining process, is not taken into account in the structural-mechanical simulation and is therefore neglected. Since the joined component geometry of the shell component is used as the virtual target geometry in the method according to the invention, the structural-mechanical simulation nevertheless takes into account or depicts the change in geometry of the shell component caused by the joining. As a result, the accuracy of the structural-mechanical simulation or of the production-related deformation calculated by means of the structural-mechanical simulation can be particularly high. In particular, because the blank is usually more deformed during the forming than the raw component is deformed during the joining process, a simulation error caused by neglecting the mechanical stresses induced during the joining process can be kept particularly low in the method according to the invention. In addition, the manufacturing-related deformation can be calculated particularly precisely, in particular in a section of the shell component that is spaced apart, in particular particularly far, from joining points of the shell component. A simulation quality of the structural-mechanical simulation, in particular in the section, can thus be particularly high.

In summary, in the structural-mechanical simulation, the jump of the joined shell component is determined, taking into account the joined component geometry of the shell component. As a result, the production-related deformation can be determined or calculated with particularly little effort. The computing time of the method according to the invention or of the structural-mechanical simulation is therefore particularly short. The structural-mechanical simulation can be used to predict or ensure the dimensional accuracy of the joined component assembly or the shell part in the joined component assembly.

When developing the shell component, it can usually be provided to simulate the forming of the blank into the shell component, that is to say to carry out the forming simulation. Thus, the result variable or the simulation result of the forming simulation for the method according to the invention can relate without additional effort hungwise with only particularly little additional effort. This can be the case in particular because the result variable or the simulation result of the forming simulation can already be available before the method according to the invention is carried out.

Provision is preferably made for the result variable of the forming simulation to be determined or calculated by means of the forming simulation. This means that the forming simulation is carried out in the process. Thus, the forming simulation can be part of the process. This means that it is preferably provided that the production-related deformation of the virtual target geometry is determined by means of the structural-mechanical simulation as a function of the result variable of the forming simulation of the raw component that maps the forming process of the production of the raw component and is carried out separately from the structural-mechanical simulation. Alternatively, the method may not include the forming simulation.

Provision is preferably made for the result variable or the simulation result of the forming simulation to be used as a boundary condition and/or as an initial condition in the structural-mechanical simulation. In other words, the production-related deformation of the virtual target geometry is determined or calculated in the structural-mechanical simulation as a function of the result variable, with the result variable being a boundary condition and/or an initial condition of the structural-mechanical simulation. As a result, the production-related deformation can be calculated particularly advantageously, in particular with particularly little effort and/or particularly precisely, as a function of the forming simulation or the simulation result of the forming simulation.

The fact that the result variable is used as a boundary condition in the structural-mechanical simulation can in particular be understood to mean that the result variable is or becomes permanently specified when or for determining the production-related deformation using the structural-mechanical simulation.

The structural-mechanical simulation can be a static or a dynamic simulation. The structural mechanical simulation is preferably a static simulation. As a result, the computing time of the structural-mechanical simulation can be kept particularly short.

The fact that the result variable is used as an initial condition in the structural-mechanical simulation can be understood in particular to mean that the result variable is or is prescribed at a start of the calculation, which is referred to in particular as the start of the simulation. For example, the structural-mechanical simulation, in particular when the structural-mechanical simulation is the dynamic simulation, includes at least two time steps, in particular a large number of time steps. In this case, the initial condition can be understood in particular as a boundary condition which is prescribed for the calculation of the production-related deformation at the first time step and thus at the start of the simulation.

In a further embodiment, it is provided that the production-related deformation is determined or calculated using the structural-mechanical simulation as a function of the result variable, which includes at least one expansion or deformation and/or at least one mechanical stress and/or at least one sheet metal thickness. In other words, the strain or the deformation and/or the mechanical stress and/or the sheet thickness is used as the result variable of the forming simulation. This means that the elongation or the deformation and/or the mechanical stress and/or the sheet thickness is a simulation result of the forming simulation. Thus, the production-related deformation is determined or calculated by means of a structural-mechanical simulation depending on the result variable, which has the elongation or the deformation and/or the mechanical stress and/or the sheet metal thickness of the formed shell component. As a result, the production-related deformation can be determined or calculated particularly precisely. This is the case in particular because expansions or deformations and/or mechanical stresses and/or changes in the sheet thickness caused during the forming of the shell component can have a particularly high influence on the component geometry of the shell component after the joining process.

The simulation result or the result variable of the forming simulation preferably characterizes a cracking of the formed raw component. In this context, springing back can be understood in particular as springing back. The crack can thus be a deformation or a change in geometry, which can occur during the forming process when the forming tool used to effect the forming is removed from the raw component after the forming Will get removed. For example, mechanical stress can be induced in the raw component during forming or by means of the forming tool, which stress leads to the springing up or springback at or after the forming process is complete. Thus, the raw component geometry can include the jump.

Provision is preferably made for the production-related deformation to be determined or calculated by means of the structural-mechanical simulation as a function of the result variable, which comprises a plurality of values, with at least one of the values corresponding to a respective partial area of a virtual, formed image of the formed raw component determined during the forming simulation is or will be assigned. In other words, the formed image of the formed raw component comprises a plurality of sub-areas, with a first of the sub-areas being assigned at least a first of the values of the result variable and a second of the sub-areas being different from the first sub-area and at least a second being being different from the first value Value of the result variable is or will be assigned. As a result, the production-related deformation can be calculated particularly advantageously by means of the structural-mechanical simulation.

The formed image of the formed raw component can be understood in particular as a shape of the formed raw component determined or calculated during the forming simulation. This means that the formed image of the formed raw component is a virtual raw component geometry of the formed raw component that is determined or calculated by means of the forming simulation. The virtual, formed image of the formed shell component can in particular be referred to as a virtual, formed image of the formed shell component. The simulation result of the forming simulation preferably includes the formed image.

The virtual reshaped image is preferably a meshed geometry. This means that the virtual, reshaped image has a plurality of, in particular a large number of, discrete elements. In other words, the reshaped image can be formed by the discrete elements.

The elements can be designed as solids or as shell elements. The respective volume body can be designed as a polyhedron, in particular as an arbitrary polyhedron. For example, the respective volume body is designed as a cuboid, as a hexahedron or as an octahedron. The volume body can in particular be referred to as a volume element.

The respective shell element is preferably designed as a polygon. For example, the polygon can be a triangle, square, hexagon, or octagon. In particular when the elements are in the form of a respective polygon, the networked, virtual, reshaped image can be referred to in particular as a polygon network. In particular when the respective element is designed as a shell element, the result variable can include the sheet metal thickness.

The respective element preferably comprises a plurality of nodes. One of the elements can be connected to an adjacent element via at least one of the respective nodes. This means that neighboring elements can share at least one of the nodes. The respective element can have at least one surface. The respective area can be at least partially delimited by respective nodes of the respective element. Thus, the respective area can be spanned between at least three nodes of the respective element.

The respective partial area can be one of the respective elements. Alternatively, the respective partial area can be one of the respective surfaces or one of the respective nodes. This means that at least one of the values of the result variable can be assigned to one of the elements, in particular an area or a node of the element. Provision can thus be made for the at least one first value to be assigned to a first of the elements, in particular a node of the first element, and to a second element that is different from the first element, in particular a node of the second element, which has at least a second value is or will be assigned.

In particular, when the respective sub-area is a respective node, the at least one first value can be or become assigned to a first of the nodes and the at least one second value can be or become assigned to a second of the nodes that is different from the first node. The first and the second node can be respective nodes of one of the elements or the first node can be a respective node of the first element and the second node can be a respective node of the second element.

Under the respective value, in particular, a respective deformation value of the deformation or a respective elongation value of the Elongation and / or a respective stress value of the mechanical stress and / or a respective thickness value of the sheet thickness are understood.

Several of the values can be or will be assigned to the respective sub-area. This means that a value pair or a value tuple is or will be assigned to the respective partial area. For example, the respective value tuple includes three values, in particular a deformation or elongation value, a stress value and a thickness value. For example, the respective value tuple includes two values. This can be the elongation or deformation value and the stress value or the elongation or deformation value and the thickness value or the stress value and the thickness value.

In a further embodiment, it is provided that the respective value is assigned to a respective sub-area of the virtual target geometry, the production-related deformation being determined or calculated by means of the structural-mechanical simulation depending on the values assigned to the sub-areas of the virtual target geometry. In other words, the respective value is transferred to the respective partial area of the respective target geometry, the production-related deformation being determined or calculated by means of the structural-mechanical simulation depending on the values transferred to the respective partial areas of the respective target geometry. As a result, the production-related deformation can be determined or calculated by means of the structural-mechanical simulation in a particularly advantageous manner, in particular particularly precisely and/or particularly with little effort.

The transmission can be understood in particular as a mapping of the respective values. The simulation result of the forming simulation, referred to in particular as forming data, can thus be transferred or mapped to the virtual target geometry in order to calculate the manufacturing-related deformation of the shell component of the joined component composite depending on the forming data using the structural mechanical simulation. This can in particular be understood to mean that in the method the joining simulation is or will be replaced by the mapping, ie the mapping is carried out instead of the joining simulation. The computing time of the method according to the invention can be kept particularly short by the mapping.

In particular when the virtual target geometry is the networked geometry, the virtual target geometry has a plurality of, in particular a large number of, discrete elements. In other words, the virtual target geometry can be formed by the discrete elements. For example, the CAD geometry of the shell component can be broken down into the discrete elements to create the meshed virtual target geometry.

The elements can be designed as solids or as shell elements. The respective volume body can be designed as a polyhedron, in particular as an arbitrary polyhedron. For example, the respective volume body is designed as a cuboid, as a hexahedron or as an octahedron. The volume body can in particular be referred to as a volume element.

The respective shell element is preferably designed as a polygon. For example, the polygon can be a triangle, square, hexagon, or octagon. In particular when the elements are designed as a respective polygon, the networked virtual target geometry can be referred to as a polygon network in particular. In particular when the respective element is designed as a shell element, the result variable can include the sheet metal thickness.

The respective element of the virtual target geometry preferably includes a number of nodes. One of the elements can be connected to an adjacent element via at least one of the respective nodes. This means that neighboring elements can share at least one of the nodes. The respective element can have at least one surface. The respective area can be at least partially delimited by respective nodes of the respective element. Thus, the respective area can be spanned between at least three nodes of the respective element.

The respective partial area can be one of the respective elements of the virtual target geometry. Alternatively, the respective partial area can be one of the respective areas or one of the respective nodes of the virtual target geometry. This means that at least one of the values of the result variable can be assigned to one of the elements, in particular an area or a node of the element. Provision can thus be made for the at least one first value to be assigned to a first of the elements, in particular a node of the first element, and to be assigned the at least one second value to a second element that is different from the first element, in particular a node of the second element is or will be.

In particular, if the respective sub-area is a respective node, the at least a first value can be assigned to a first one of the nodes and a second one of the nodes different from the first node can become the at least one second value. The first and the second node can be respective nodes of one of the elements or the first node can be a respective node of the first element and the second node can be a respective node of the second element.

In a further refinement, it is provided that the respective value is assigned to that sub-area which in an imaginary projection of the reshaped image onto the virtual target geometry is the closest distance from the respective sub-area of the reshaped image. In other words, the respective location coordinates of the respective sub-area and the respective sub-area are compared with one another, with the value assigned to the respective sub-area being assigned to that sub-area whose location coordinate is the shortest distance from the location coordinate of the respective sub-area.

This can in particular be understood to mean the following: A respective geometry of the virtually formed image and the virtual desired geometry is preferably different from one another. As a result, in particular, the respective sub-areas can be different from the respective sub-areas. This means that the sub-areas could not be arranged congruently on the respective sub-areas in the imaginary projection. For this reason, when the respective values are transmitted, that sub-area is selected which is arranged closest to the respective sub-area in the imaginary projection. This means that the value of the respective sub-area is assigned to that sub-area or transferred to that sub-area which is arranged closest to the respective sub-area. As a result, the production-related deformation can be determined particularly precisely using the structural-mechanical simulation.

The respective location coordinate can be understood in particular as a position of the respective partial area or the respective partial area on the virtual formed image or the virtual target geometry. In this case, the respective location coordinate can in particular be a vector which includes several, in particular all, coordinates of the respective spatial direction. For example, a distance between the partial area and the partial area can be calculated from a difference in the respective position vector of one of the partial areas and one of the partial areas. This can be done for all sub-areas and sub-areas, for example. Subsequently, respective pairs of a respective partial area and a respective partial area can be determined, with the respective pair having the smallest calculated distance in each case. This makes it possible to determine which of the respective partial areas is the closest to the respective partial area in the imaginary projection onto the virtual target geometry.

In a further embodiment it is provided that depending on the respective value assigned to the respective sub-area of the virtual target geometry, of a respective position of the respective sub-area on the formed image and of a respective position of the respective sub-area on the virtual target geometry a respective corrected value is determined or calculated, with the production-related deformation being determined or calculated as a function of the corrected values by means of the structural-mechanical simulation. In other words, the respective value assigned to the respective sub-area of the virtual target geometry, the respective position of the respective sub-area on the reshaped image and the respective position of the respective sub-area on the virtual target geometry are respective input variables for determining the respective corrected value, the respective corrected value being determined or calculated as a function of the input variables. The corrected values are then used as the input variable for the structural-mechanical simulation, whereby the production-related deformation is calculated or determined as a function of the corrected values. This means that the production-related deformation is determined by means of the structural-mechanical simulation indirectly as a function of the respective value assigned to the partial area of the virtual desired geometry. This is the case in particular because the respective corrected value is determined as a function of the respective value assigned to the respective partial area of the virtual target geometry. By taking into account the corrected values for or during the structural-mechanical simulation, the production-related deformation can be determined particularly precisely using the structural-mechanical simulation. This means that an error in the structural-mechanical simulation, in particular a discretization error, can be kept particularly small.

The respective position can be understood in particular as the respective spatial coordinates or the respective location. Provision is preferably made for the virtual target geometry, in which the production-related deformation is determined or calculated by means of the structural-mechanical simulation, to be the image or the image of the component geometry is, which has the shell part in the joined component composite, in which the shell part is connected to the separately formed from the shell part, second shell part or the component by means of flanging. In other words, the joined component assembly is a flanged component assembly, whereby the joined component geometry of the shell part is a flanged component geometry of the shell part, which the shell part has in the flanged component assembly, the flanged component geometry being used as the virtual target geometry of the shell part. This means that the joining process is a flanging process. In particular because the computing time of the flanging simulation can be particularly high, the computing time for determining the production-related deformation can be kept particularly short in the method. As a result, the production-related deformation can be determined with particularly little effort.

Alternatively, the joining process can be a joining method that differs from flanging, for example welding, in particular laser welding. Thus, the virtual target geometry, in which the production-related deformation is determined or calculated by means of the structural-mechanical simulation, can be an image or an image of the component geometry, which has the shell part in a welded component composite, in which the shell part with the separately from the shell part formed second raw part or the component by means of welding, in particular laser welding, is connected.

In a further embodiment, it is provided that the virtual target geometry is held at at least one, in particular virtual, bearing point during the structural-mechanical simulation. In other words, it can be provided that in the structural-mechanical simulation at least one point of the virtual target geometry is prescribed as a boundary condition that a movement or displacement of the point does not occur when determining the production-related deformation or in the structural-mechanical simulation. As a result, the production-related deformation can be calculated particularly precisely. This means that the production-related deformation can be mapped particularly realistically or realistically.

The point can be understood in particular as one of the respective partial areas, in particular a respective node, of the virtual target geometry. The point is preferably arranged on an edge area of the virtual target geometry.

During the forming simulation, the virtual formed image is preferably held at at least one, in particular virtual, bearing point of the forming simulation. The respective bearing conditions of the bearing point of the structural-mechanical simulation and of the bearing point of the forming simulation are preferably the same or similar. As a result, the jump can be calculated particularly precisely in the structural-mechanical simulation.

The respective storage condition can be understood in particular as a type of respective virtual storage and/or a respective position of the respective storage point on the respective partial area or the respective partial area. The respective bearing type can in particular be understood as meaning in which spatial directions movements and/or rotations are restricted or permitted by the virtual bearing.

The method according to the invention was explained as an example for the shell component. Of course, the method according to the invention can also be carried out using the component or the second shell component.

Further features of the invention result from the claims, the figures and the description of the figures. The features and combinations of features mentioned above in the description and the features and combinations of features mentioned below in the description of the figures and/or shown alone in the figures can be used not only in the combination specified in each case, but also in other combinations or on their own.

• 1 ein schematisches Verfahrensdiagramm eines erfindungsgemäßen Verfahrens; und
• 2 eine schematische Teilschnittansicht eines Bauteilverbunds für ein Kraftfahrzeug; und
• 3 eine schematische Draufsicht eines Rohbauteils; und
• 4 eine schematische Perspektivansicht einer gefügten Bauteilgeometrie eines Rohbauteils, wobei das Rohbauteil in einem gefügten Bauteilverbund die gefügte Bauteilgeometrie aufweist; und
• 5 eine schematische Draufsicht einer virtuellen Soll-Geometrie des Rohbauteils und eine schematische Draufsicht eines virtuellen, umgeformten Abbilds eines umgeformten Rohbauteils; und
• 6 eine jeweilige schematische Draufsicht zur Veranschaulichung von Teilbereichen eines virtuellen umgeformten Rohbauteils und Teilgebieten einer virtuellen Soll-Geometrie des Rohbauteils; und
• 7 ein schematisches Verfahrensdiagramm eines erfindungsgemäßen Verfahrens gemäß einer weiteren Ausführungsform; und
• 8 eine schematische Draufsicht einer virtuellen Soll-Geometrie des Rohbauteils zur Veranschaulichung von virtuellen Lagerpunkten.

The invention will now be explained in more detail using a preferred exemplary embodiment and with reference to the drawings. Show it:

• 1 a schematic process diagram of a method according to the invention; and
• 2 a schematic partial sectional view of a component assembly for a motor vehicle; and
• 3 a schematic plan view of a shell; and
• 4 a schematic perspective view of a joined component geometry of a shell component, wherein the shell component has the joined component geometry in a joined component composite; and
• 5 a schematic top view of a virtual target geometry of the shell part and a schematic top view of a virtual, formed image of a formed raw part; and
• 6 a respective schematic plan view to illustrate partial areas of a virtual formed shell part and partial areas of a virtual target geometry of the shell part; and
• 7 a schematic process diagram of a method according to the invention according to a further embodiment; and
• 8th a schematic plan view of a virtual target geometry of the shell to illustrate virtual bearing points.

Elements that are the same or have the same function are provided with the same reference symbols in the figures.

1 shows a schematic method diagram of a method for determining or calculating a production-related deformation 1 of a shell component 2 of a joined composite component 3 of a motor vehicle. 2 shows the assembled component 3 in a particularly schematic partial sectional view. The joined structural component 3 comprises the shell component 2 and a second shell component 4 formed separately from the shell component 2. In the joined component composite 3, the shell component 2 and the second shell component 4 are connected to one another. This means that when the joined composite component 3 is produced, the shell component 2 and the second shell component 4 are connected to one another by means of joining.

For example, the body shell 2 is designed as an outer skin of a body shell, in particular a body, of the motor vehicle. For example, the second body shell 4 is designed as an inner panel of the body shell, in particular the body. Alternatively, the shell component 2 can be designed as the inner panel and the second shell component 4 as the outer skin. The shell component 2 is preferably designed as a front flap of the motor vehicle.

The respective raw component 2, 4 is preferably produced by means of forming. This means that the raw component 2 is produced, for example, from a blank by reshaping the blank. After the forming, the raw component 2 has a shape, referred to in particular as the raw component geometry 5, which differs from a shape of the blank. 3 1 shows the formed shell part 2 or the shell part geometry 5 in a schematic plan view. The formed shell component 2, which has the shell component geometry 5, is deformed during the joining or by the joining, as a result of which the shell component 2 in the joined component composite 3 has a joined component geometry 6, which is different from the blank and the shell component geometry 5. 4 shows the raw component 2 in the joined component geometry 6 in a schematic perspective view.

In the exemplary embodiment, the joining involves flanging. This means that the raw components 2, 4 are connected to one another by means of flanging to form the joined composite component 3. The joined composite component 3 can thus be referred to in particular as a flanged composite component 3 . Thus, the component geometry 6 is a component geometry which the shell part 2 has in the flanged component assembly 3, in which the shell part 2 is connected to the second shell part 4, which is formed separately from the shell part 2, by means of flanges.

For example, the joined component geometry 6 in the flanged component assembly includes a flanged flange. This crimped flange can be formed when crimping. The flanged component geometry 5 can thus differ from the shell component geometry 5 in particular by the flanged flange. For example, an open flange of the shell component geometry 5 can be formed into the flanged flange during flanging.

The production-related deformation 1 of the shell part 2 can be understood in particular as a deformation which the shell part 2 undergoes during joining and in particular during forming. In order to be able to make statements regarding the dimensional accuracy of the joined component assembly 3 in a development process of the joined component assembly 3, simulation can be used. The production-related deformation 1 of the shell component 2 of the joined composite component 3 can be determined or calculated by means of the simulation. The determined production-related deformation 1 or the virtual joined shell component 2 determined with the simulation can then be compared with a target status. This comparison can be used to check or ensure the dimensional accuracy of the joined component assembly 3 .

In order to be able to determine or calculate the production-related deformation 1 of the shell component 2 of the joined component assembly 3 with particularly little effort, the method provides for using a structural mechanical simulation 7 to determine the production-related deformation 1 of a virtual target geometry 8 as a function of at least one result variable 9 a forming process, in particular at least one Manufacturing step, a production of the shell part 2 mapping and separate from the structural mechanical simulation 7 feasible or carried out forming simulation 10 of the shell part is determined. This means that the result variable 9 simulated using the forming simulation 10 is an input variable for determining the production-related deformation 1 using the structural-mechanical simulation 7 . In the case of the structural-mechanical simulation 7, the production-related deformation 1 of the virtual target geometry 8 is calculated.

5 shows the virtual target geometry 8 in a first schematic plan view A. The virtual target geometry 8 is a or an image of the joined component geometry 6, which the shell part 2 has in the joined component composite 3. This means that in the structural-mechanical simulation 7 the joined component geometry 6 caused by the joining is taken into account, the production-related deformation 1 being calculated as a function of the result variable 9 and thus as a function of a simulation result of the forming simulation 10 . The production-related deformation 1 determined by means of the structural-mechanical simulation 7 thus includes an influence of the forming process or the forming of the shell component. In addition, the production-related deformation 1 determined by means of the structural-mechanical simulation 7 includes an influence of the joining, in particular the flanging, or the joining process on the formed raw component 2, namely the change in geometry of the raw component 2 caused by the joining or flanging. This is the case in particular since the virtual target geometry 8 is used in the structural-mechanical simulation 7, which depicts the joined component geometry 6. As a result, the production-related deformation 1 can be determined without a joining simulation, in particular flanging simulation, of the joining, in particular flanging, of the shell components 2, 4, which can in particular be carried out separately from the structural-mechanical simulation 7 and the forming simulation 10. In particular because such a joining simulation, in particular a flanging simulation, can be computationally particularly complex, the computing time for determining the production-related deformation 1 can be kept particularly short. As a result, the production-related deformation 1 can be determined with particularly little effort. As a result, the dimensional accuracy of the shell component 2 in the joined composite component 3 can be ensured with particularly little effort.

This means that, compared to a conventional method in which the joining simulation, in particular the flanging simulation, can be carried out, mechanical stresses caused by the joining, in particular flanging, in the raw component 2 of the joined component composite 3 are neglected when determining or calculating the deformation 1 caused by production become. In particular because these mechanical stresses can be particularly low compared to the mechanical stresses induced in the blank or the formed raw component 2 during the forming process, the manufacturing-related deformation 1 can nevertheless be determined particularly precisely in the method. In addition, the mechanical stresses caused by flanging are usually induced in the raw component 2 in the region of the flanging. Mechanical stresses caused by the flanging are therefore usually particularly low or non-existent in sections remote from the flanged flange. For this reason, the production-related deformation 1 can be determined particularly precisely in the joined component composite 3 by means of the structural-mechanical simulation 7, in particular in sections of the shell component 2 that are at a distance or removed from the flanged flange.

The forming simulation 10 is a single-part simulation of the forming process during the production of the shell part 2. This means that the entire joined component composite 3 is not simulated in the forming simulation 10, but in particular only the shell part 2. The structural-mechanical simulation 7 is also a single-part simulation. This means that the entire assembled component assembly 3 is not simulated in the structural-mechanical simulation 7, but in particular only the shell component 2, which has the assembled component geometry 6 in the structural-mechanical simulation 7.

Provision is preferably made for the result variable 9 to be used as a boundary condition 12 and/or as an initial condition 13 in the structural-mechanical simulation 7 . As a result, the result variable 9 can flow particularly advantageously into the structural-mechanical simulation 7, as a result of which the production-related deformation 1 can be calculated particularly advantageously, in particular particularly precisely.

In a further embodiment, it is provided that the production-related deformation 1 is determined or calculated by means of the structural-mechanical simulation 7 depending on the result variable 9, which is at least one deformation or strain 14 and/or at least one mechanical stress 15 and/or at least one sheet metal thickness 16 of the formed shell part 2 includes. This means that in the forming simulation 10 simulated or calculated strain 14 and/or mechanical stress 15 and/or sheet thickness 16 is used as an input variable for the structural-mechanical simulation 7 . Thus, the strain 14 and/or the mechanical stress 15 and/or the sheet thickness 16 can be used as a boundary condition 12 and/or as an initial condition 13 in the structural-mechanical simulation 7 . The elongation 14 and/or the mechanical stress 15 and/or the sheet metal thickness 16 of the formed shell component 2 can have a particularly high influence on the joined component geometry 6 of the shell component 2 . The production-related deformation 1 can thus be calculated particularly precisely by means of the structural-mechanical simulation 7 .

The simulation result of the forming simulation 10 preferably includes a virtual, formed image 17 determined during the forming simulation 10 or a formed image of the formed raw component 2. 5 shows the virtual reshaped image 17 in a second schematic plan view B. In 5 the open flange is shown in a first detailed view C and the crimped flange is shown in a second detailed view D.

The forming simulation 10 is preferably a numerical simulation, for example a finite element simulation. In this case, the virtual, formed image 17 preferably comprises a multiplicity of sub-areas 18. The respective sub-area 18 is preferably a respective, in particular discrete, element. The sub-areas 18 or the elements are in 5 shown in the first detailed view C. The respective element or the respective partial area 18 is preferably designed as a respective shell element. In particular when the respective element is designed as a shell element, the result variable 9 can include the sheet metal thickness 16 .

6 12 shows, in a schematic top view referred to in particular as the third top view E, the partial areas 18 of the virtual formed image 17 configured as a respective element. The respective element or the respective partial area 18 preferably comprises at least one surface 18a. The respective element or the respective partial area 18 preferably comprises a plurality of nodes. This is shown as an example for a first of the elements or partial areas 19, which has a plurality of nodes 19a-d. Another of the partial areas 18 that differs from the first partial area 18 can in particular be referred to as the second partial area 20 .

7 shows a schematic process diagram of the process according to a further embodiment, in which the result variable 9 comprises a plurality of values 21, 22. At least one of the values 21, 22 is preferably assigned to one of the respective partial areas 18 of the virtual, formed image 17 of the formed raw component 2 determined in the forming simulation 10.

For example, a first of the values 21 is assigned to the first sub-area 19, in particular to one of the nodes 19a-d of the first sub-area 19, and a second of the values 22 is assigned to the second sub-area 20, in particular to a node of the second that is different from the nodes 19a-d Portion 20 of the virtual reshaped image 17 assigned. Alternatively, the first value 21 can be assigned to a first of the nodes 19a of the first subarea 19 and the second value 22 can be assigned to a second node 19b of the first subarea 19 that is different from the first node 19a.

The structural mechanical simulation 7 is preferably a numerical simulation, for example a finite element simulation. In this case, the virtual target geometry 8 preferably comprises a multiplicity of partial regions 24. The respective partial region 24 is preferably a respective, in particular discrete, element. The sub-areas 24 or the elements are in 5 shown in the second detailed view D. The respective element or the respective partial region 24 is preferably designed as a respective shell element. In particular when the respective element is designed as a shell element, the result variable 9 can include the sheet metal thickness 16 or the sheet metal thickness can be used as an input variable for the structural-mechanical simulation 7 .

6 FIG. 12 shows, in a further schematic plan view designated in particular as the fourth plan view F, the partial regions 24 of the virtual target geometry 8 configured as a respective element. The respective element or the respective partial region 24 preferably comprises at least one surface 24a. The respective element or the respective partial area 24 preferably comprises a plurality of nodes. This is shown as an example for a first of the elements or a first of the partial regions 25, which has a plurality of nodes 25a-d. Another of the sub-regions 24 that differs from the first sub-region 25 can in particular be referred to as the second sub-region 26 .

Provision is preferably made for the respective value 21, 22 to be assigned to the respective partial area 24 of the virtual target geometry 8, the production-related deformation 1 being determined or calculated by means of the structural-mechanical simulation 7 depending on the values 21, 22 assigned to the partial regions 24 of the virtual desired geometry 8. The result variable 9 or the simulation result determined from the forming simulation 10 is thus transferred or mapped to the virtual target geometry 8 .

For example, the first value 21 assigned to the first partial area 19 is assigned to the first partial area 25, in particular to one of the nodes 25a-d, and the second value 22 assigned to the second partial area 20 is assigned to the second partial area 26, in particular to one of the nodes 25a-d. d different nodes of the second sub-area 26 assigned. Alternatively, the first value 21 assigned to the first node 19a of the first subarea 19 can be assigned to a first of the nodes 25a of the first subarea 25 and the second value 22 assigned to the second node 19b of the first subarea 19 can be assigned to a second of the nodes 25b of the first subarea 25 are assigned. The production-related deformation 1 can be determined or calculated by means of the structural-mechanical simulation 7 depending on the values 21, 22 assigned to the nodes 25a, 25b.

The respective value 21, 22 is preferably a respective elongation value of the elongation 14 or a respective stress value of the mechanical stress 15 or a respective thickness value of the sheet thickness 16. Alternatively, instead of the respective value 21, 22, a respective value tuple can be used which contains the elongation value and/or or may include the stress value and/or the thickness value.

In a further embodiment, it is provided that the respective value 21, 22 is assigned to that partial region 24 or 25, 26, in particular the respective node 25a-d, which in an imaginary projection of the formed image 17 onto the virtual target geometry 8 closest to the respective partial area 18 or 19, 20, in particular from the respective nodes 19a-d, of the reshaped image 17. This can be understood to mean the following in particular: For example, each of the partial areas 18 has a respective position 27 on the virtual formed image 17 and the respective partial area 24 has a respective position 28 on the virtual target geometry 8 . In 6 the respective positions 27, 28 are sketched as examples for the first partial area 19 and the first partial area 25. In the exemplary embodiment, a respective center point of the sub-area 19 or of the sub-area 25 is used for the respective position 27, 28. The respective position 27, 28 can be described by means of a respective location vector 29, 30. For example, a first of the location vectors 29 is related to a coordinate system 31 of the virtual formed image 17 and a second of the location vectors 30 is related to a coordinate system 32 of the virtual target geometry 8 . The coordinate systems 31, 32 are preferably identical. The respective location vectors 29, 30 can be used to calculate distances between the respective partial area 18 and the respective partial area 24. In order to determine the respective distance, an amount is calculated, for example, from a difference in the position vectors 29,30. The value 21, 22 assigned to the respective partial area 18 is preferably assigned to the respective partial area 24 in the case of that partial area 18 and that partial area 24 which are at the smallest distance from one another.

In a further embodiment, it is provided that depending on the respective value 21, 22 assigned to the respective partial region 24 or 25, 26, in particular the respective node 25a-d, of the virtual target geometry 8 and depending on the respective position 27 of the respective sub-area 18 or 19, 20, in particular from the respective node 19a-d, on the reshaped image 17 and depending on the respective position 28 of the respective sub-area 24 or 25, 26, in particular from the respective node 25a-d, on the A respective corrected value 33, 34 is determined or calculated from the virtual target geometry 8, with the deformation 1 caused by production being determined or calculated by means of the structural-mechanical simulation 7 as a function of the corrected values 33, 34. This means that the respective value 21, 22 and the respective positions 27, 28 are respective input variables, with the respective corrected value 33, 34 being calculated as a function of the input variables, by means of which the production-related deformation 1 is determined in the structural-mechanical simulation 7, respectively is calculated. The respective corrected value 33, 34 is preferably provided to take into account a deviation between the respective positions 27, 28. This means that, for example, the corrected value 33 is calculated as a function of a distance or a difference between the position 27 of the first partial area 19 and the position 28 of the first partial area 25 . The location vectors 29, 30 are preferably used for this. Interpolation and/or extrapolation is preferably used to determine the corrected values 33, 34.

By using the corrected values 33, 34 in the structural simulation 7 a spatial discretization error between the virtual image 17 and the virtual target geometry 8 can thus be kept particularly low. As a result, the production-related deformation 1 can be determined particularly precisely by means of the structural-mechanical simulation 7 .

For example, a first of the corrected values 33 is calculated as a function of the first value 21 and of the respective positions 27, 28. For example, a second of the corrected values 34 is calculated as a function of the second value 22 and of the respective positions 27, 28.

8th shows the virtual target geometry 8 in a schematic top view, with 8th virtual bearing points 35 are illustrated. Provision is preferably made for the virtual target geometry 8 to be held at at least one of the virtual bearing points 35 during the structural-mechanical simulation 7 . As a result, the production-related deformation 1 can be determined particularly precisely by means of the structural-mechanical simulation 7 .

Reference List

1

deformation

2

shell part

3

component composite

4

second raw part

5

shell geometry

6

component geometry

7

structural simulation

8th

virtual target geometry

9

result size

10

forming simulation

11

Illustration

12

boundary condition

13

initial condition

14

strain

15

Tension

16

sheet thickness

17

image

18

subarea

18a

Surface

19

first section

19a

first knot

19b

second knot

19c

node

19d

node

20

second section

21

first value

22

second value

24

sub-area

24a

Surface

25

first part

25a

first knot

25b

second knot

25c

node

25d

node

26

second area

27

position

28

position

29

location vector

30

location vector

31

coordinate system

32

coordinate system

33

first corrected value

34

second corrected value

35

storage point

A

first top view

B

second top view

C

first detailed view

D

second detail view

E

third top view

f

fourth top view

Claims (9)

Method for determining a production-related deformation (1) of a shell component (2) of a joined composite component (3) of a motor vehicle, in which the production-related deformation (1) of a virtual target geometry (8), which is an image (11) of a component geometry (6) which the raw component (2) has in the joined component composite (3), depending on at least one result variable (9) of a forming process of a production of the raw component (2) that depicts and separately from the structural-mechanical Simulation (7) feasible forming simulation (10) of the shell part (2) is determined. procedure after claim 1 , characterized in that the result variable (9) is used in the structural-mechanical simulation (7) as a boundary condition (12) and/or as an initial condition (13). procedure after claim 1 or 2 , characterized in that the production-related deformation (1) is determined by means of the structural-mechanical simulation (7) as a function of the result variable (9), which is at least one strain (14) and/or at least one mechanical stress (15) and/or at least includes a sheet thickness (16). Method according to one of the preceding claims, characterized in that the production-related deformation (1) is determined by means of the structural-mechanical simulation (7) as a function of the result variable (9), which comprises a plurality of values (21, 22), one of the values in each case (21, 22) is assigned to a respective partial area (18) of a virtual, formed image (17) of the formed shell component (2) determined during the forming simulation (10). procedure after claim 4 , characterized in that the respective value (21, 22) is assigned to a respective sub-area (24) of the virtual target geometry (8), the structural-mechanical simulation (7) depending on the sub-areas (24) of the virtual target - Geometry (8) associated values (21, 22) the production-related deformation (1) is determined. procedure after claim 5 , characterized in that the respective value (21, 22) is assigned to that sub-area (24) which is closest to the respective sub-area (18 ) of the deformed image (17) is spaced. procedure after claim 5 or 6 , characterized in that depending on the respective value assigned to the respective partial area (24) of the virtual target geometry (8), from a respective position (27) of the respective partial area (18) on the formed image (17) and from a A respective corrected value (33, 34) is determined from the respective position (28) of the respective partial area (24) on the virtual target geometry (8), whereby depending on the corrected values (33, 34) by means of the structural-mechanical simulation (7th ) the manufacturing-related deformation (1) is determined. Method according to one of the preceding claims, characterized in that the virtual target geometry (8), in which the production-related deformation (1) is determined by means of the structural-mechanical simulation (7), is an image (11) of a component geometry (6), which has the shell component (2) in the joined component composite (3), in which the shell component (2) is connected by means of flanging to a second shell component (4) which is formed separately from the shell component (2). Method according to one of the preceding claims, characterized in that the virtual desired geometry (8) is held at at least one bearing point (35) during the structural-mechanical simulation (7).

Images