Advanced virtual process: Thermomechanical finite element analysis along car body manufacturing process

Title: Advanced virtual process: Thermomechanical finite element analysis along car body manufacturing process. Abstract: Car is one of the most complex engineering systems. Undoubtedly, among all the macrosystems of which a car is made up, its body is the most important. Indeed, car body is the first macrosystem to be revised when a new challenge for automotive sector present itself. Therefore, this work, firstly, describes how this macrosystem is currently structured and the processes by which car body is manufactured; secondly, it analyses the impact of a strong drive on material selection, using two different perspectives. Indeed, initially, it is adopted an external perspective by which data related to car bodies (made available by car makers participating in the EuroCarBody Convention from 2015 to 2017) are shown; lastly, it is adopted an internal perspective, analyzing FCA reaction with Alfa Romeo Giulia. Afterward it is highlighted how today's digital industrial scenario provides some tools that allow a virtual validation of a product or a process. In particular, the finite element method, as a powerful tool for complex physical phenomena analysis, is illustrated. Hence, an industrial application of this method is shown, describing in detail thermomechanical analysis carried out in FCA for the virtual quality control of a car body component such as the hood. After, how it is possible to obtain a better control on product quality by identifying the influence of process parameters on the product is emphasized by a sensitivity and significance analysis. In conclusion an optimization strategy, which allows to meet FCA quality standards, is presented.