Identifying Critical Areas for Styling Data Based Simulation to Evaluate Perceived Quality Related to Non-Rigidity

When handling mass-produced parts in the automotive industry it is of great importance to take into consideration the geometrical variation that will occur as a result of the manufacturing process used. By using a Computer Aided Tolerancing (CAT) software, effects of geometrical variation are simulated to support robust design. As an additional step, simulated results may be evaluated in a high-end visualization tool to judge a predicted outcome of the final Perceived Quality (PQ). PQ is an overall quality impression perceived by the product user. However, when a new styling concept is evaluated the data used for analysis and visualization will be less mature in terms of component design. Design parameters such as material selection, material thickness, locating scheme, design and position of reinforcements and flanges are rarely defined here. These parameters influence the deformation behavior of a component which is critical for the outcome of the variation simulation. Previously presented methods for variation simulation of non-rigid parts are FEA-based, a method that are strongly dependent on these design parameters for a reliable result. A method of how to handle these uncertainties by using information from earlier design solutions, preferably based on the same platform, and applying them to current styling has earlier been suggested by the authors.In this paper, the result from a descriptive study carried out at a Swedish automobile manufacturer is presented. The objective of the study was to identify areas where PQ is most frequently evaluated with non-rigidity in components as a contributing factor. This will on one hand indicate where non-rigid variation simulation is most critical for a more reliable prediction of the final PQ. On the other hand, it will support the further development of the above mentioned method, as diverse approaches may be necessary for different areas on the vehicle