Application of Advanced Measuring Methods for Identification of Stresses and Deformations of Automotive Structures

Abstract

In the automotive industry, 3D laser scanning is the most frequently used method to check the geometry of the shape and dimensions of a body in individual stages of production, where the scanned model is compared in a computer model. This procedure identifies excessive deformations around the roof antenna of an SUV. The manufacturer assumed that these deformations occurred during the antenna assembly process. An analysis of possible causes of deformation occurrence was performed based on the comparison of results obtained by numerical and experimental modelling. Experimental measurements using tensometry performed on a painted and unpainted roof structure showed the effect of paint reinforcement on deformations around the antenna. Based on the analysis of results obtained directly under operational load, it was found that the installation of the antenna was carried out on the already deformed roof plate and the installation process itself was not the primary cause of the identified excessive deformations. The presented results of deformation and stress analysis document deeper connections between the measured displacements of 3D scanning and the technological process of component production itself. The use of the achieved results should especially help designers, calculators, technologists as well as production quality controllers.

Keywords

• 3D scanning
• stress analysis
• tensometry
• numerical modelling
• residual stresses