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Technical Briefs

Using Volume Morphing to Alter Panel Designs to Compensate Shape Distortion in Assembly

[+] Author and Article Information
Ramon F. Sarraga

 General Motors Research and Development, Warren, MI 48090rsarraga@gmail.com

Paul A. LeBlanc

 Hewlett-Packard Company, Palo Alto, CA 94304pleblanc@acm.org

Thomas J. Oetjens

 General Motors North America Product Development, Warren, MI 48090oetjens3@aol.com

J. Comput. Inf. Sci. Eng 10(2), 024501 (Jun 08, 2010) (4 pages) doi:10.1115/1.3402683 History: Received March 25, 2009; Revised March 16, 2010; Published June 08, 2010; Online June 08, 2010

As automotive panels are assembled in a vehicle, they are subjected to shape distorting forces, e.g., the pressure of door seals. A standard technique for preventing shape distortions is to alter the panels’ computer aided design (CAD) in such a way that the panels assume the desired design shape under the action of the distorting forces. Volume morphing, a technique pioneered by Bézier (1978, “General Distortion of an Ensemble of Biparametric Patches,” Comput.-Aided Des., 10(2), pp. 116–120) and by Sederberg and Parry (1986, “Free-Form Deformation of Solid Geometric Models,” International Conference on Computer Graphics and Interactive Techniques, Proceedings of the 13th Annual Conference on Computer Graphics, pp. 151–160), has been extended and implemented in a computer software package called FESHAPE , created at the General Motors Research and Development Center. FESHAPE automatically modifies CAD models according to a finite set of displacement vectors obtained, e.g., from finite-element analysis or scanning tryout parts. This article discusses how FESHAPE has been successfully applied to compensate door panel distortion caused by door seals.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Cross-sectional sketch of a closed door pushed outward (proud) from the vehicle frame by a seal

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Figure 2

ABAQUS finite-element mesh showing the nodes (black numbers) selected to define a FESHAPE overbend operation

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Figure 3

Designer view in Siemens NX of the overbend operation. The rectangular boxes denote the local morphing volume. The morphed portion of the door is inside the boxes.

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Figure 4

A plane (horizontal line) is fitted to four FE nodes. A normal (vertical) reference line is drawn through each FE node, and translations of that node’s displacement vector are placed along the reference line. (Only two translations of a single node are shown.)

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Figure 5

Siemens NX screen picture showing (a) the translated FE-node displacements generated inside a local box, (b) the plane fit to the node points (flat, dark), and (c) a visible part of the door’s CAD model (lighter shade)

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Figure 6

The Siemens NX solid model of the morphed door is divided into an overbent portion (inside boxes) and an unchanged portion (outside the outer box)

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