Virtual Manufacturing Empowers

Digital Product Development

Case Study E-Coat Simulation
Frank Pfluger Klaus Wechsler
Abstract

Recent progress in simulation methods for the manufacturing industry has reduced the
need for expensive test hardware which could be gratis used in manufacturing. Using
manufacturing simulation tools starting at the design stage helps to optimize product
development and corresponding manufacturing systems. Whenever there is a need for
an early design input in order to ensure quality and manufacturing costs - virtual
manufacturing methods will have a profitable chance.

For the case study E-Coat simulation STAR-CCM provides an improved workflow from
CAD-data and meshing to E-coat deposition as well as modeling of fill and drain
behaviors in vehicle paint shops. Simulation results provide the design engineer with
answers to questions such as ´is the E-Coat providing corrosion protection in all the
cavities´? or ´is there a corrosion risk based on air bubbles or paint ponds´?

The combination of an implemented fast algorithm with the chance of describing

customer developed material properties by Field Functions allows best fit to complex
chemical material behavior. Customized material development is kept inside
customers. Based on process knowledge we are also providing multiple simulation
support.
An overview of future manufacturing simulation topics will be given.

2
Virtual Manufacturing is a Consequence of
Hardware Reduced Digital Product Development

Doing it in a physical way takes too long.

Whenever there is a need for an early design input in order to ensure
quality and manufacturing costs:
Virtual Manufacturing methods will have a profitable chance.

3
The E-Coat Deposition Process Provides
Corrosion Protection in all Cavities

4
Overview of the E-Coat Simulation Steps

Data Freeze of BIW-Meshing Dipping in: E-Coat Dip-Tank Dipping Out

Digital Product ( for ex. Wrapper, (Air Bubbles, (Paint Thickness on (Puddles, Drainage -
Development Boolean Unite) Pressure Distribution) surfaces and cavities) Time, Pressure Distr.)

Suggestions for Design Optimization

Goal: Corrosion protective E-Coat thickness, minimized
air bubbles and puddles in all parts and cavities….)

5
E-Coat Modeling: Deposition of charge carrying paint polymers.
Increasing resistance gives a chance for deposition inside cavities

E-Coat
Paint material:
..solids (pigments, resin/binder,.),
solvent (de-ionized water) and co-solvents Electrolyte
(glycol ether..)
Conductivity is mainly based on the
resin fraction but sensitive to carryover BIW=Cathode
of conductive pre treatment materials
from previous dipping steps ..

Electro Static Paint

6
E-Coat Modeling: ..a small Chemical Plant..

Anode

- Anode:
Anolyte Circulation with influence
on pH and film re-dissolution.
- Dip Tank:
Mixture of old (aged) and new material
as well as recirculation from Rinse Tank.
Needs permanent agitation and precise
temperature control.
- Pretreatment:
Carryovers affect conductivity.

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Equations of the STAR-CCM+ Standard
Electro-Deposition Model
ℎ
  jn  jmin 
dh PL c P dR PL dh PL Paint layer thickness in m
   rP
dt ρP dt dt Paint layer resistance in Ωm2

  j  q0 q  q
 n jif qif Specific electric current in A/m2
j min  0  if q  q0 with q0 0  with
jmin   n j  n dt
q j dt
if q  q 0
n
0
Input Parameters of Standard Range of Values form
Deposition Model calibration measurements

cP: Coulomb efficiency 2-4·10-5 kg/As

ρP: Paint layer density 1200-1800 kg/m³

rP: Paint layer resistivity 2-5·106 Ωm

q0: Minimum Accumulated ´Activation Charge ´which

is necessary to start deposition in standard material) 300-400 As/m²
There is no deposition as long as q<q0

σliquid: Bath (Electrolyte) conductivity 0.14-0.22 S/m

8
Example of Enhanced (Customized) Electro-Deposition Model
Using Field Functions for Detailed Calibration Measurements

ℎ
  jn  jmin 
dh PL c P dR PL dh PL Paint layer thickness in m
   rP
dt ρP dt dt Paint layer resistance in Ωm2

 j if J 2  J 02
Specific electric current in A/m2
 n  
2
jmin with J j2n dt Electric Potential at top of paint layer
 0 if J  J0
2 2
( ) in V

Input Parameters of Enhanced Deposition Cp(t) = f( ( ), (t))

Model: - Variable Coulomb Efficiency Cp (fb, C2u, C1u, C0u = based on detailed
2 2
- Deposition Starts if J > J0 calibration measurements)
cP: Coulomb efficiency (1-exp(- ))*(fb*exp(- /h0))+(-C2U U²+C1U U+C0U)
* *
ρP: Paint layer density 1200-1800 kg/m³

rP: Paint layer resistivity 2-5·106 Ωm

2
J0 : Minimum Accumulated ´Activation Work ` (which is
necessary to start deposition. A2s/m4
2 2
There is no deposition as long as J < J0

σliquid: Bath (Electrolyte) conductivity 0.14-0.22 S/m

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Calibration of E-Coat Simulation Parameters:
(1) Using Existing Real Parts (if CAD Data are Available)

Outside: Inner:
x = 25 µm x = 18 µm

Hidden:
x = 8 µm

Where can these data be found: E-Coat Thickness (µm) x

- Sometimes paint shop regularly opens x = measurement
parts for quality assurance x
- Durability and other testing departments
might have opened parts x
Calibration:
- Mesh real part and tank and adjust the
parameters of the deposition model until
´best parameter fit´ is reached. Provides a fast pragmatic calibration with
- Use conductivity and paint layer density focus to final (corrosion relevant) thickness
from direct measurement/supplier.
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Calibration of E-Coat Simulation Parameters:
(2) Using Calibration Tubes Fixed to an Existing Part

x = measurement

Preparation:
- Tubes are fixed to a part being coated
- Tubes are opened and measured inside

Calibration:
- CAD model of tubes should be added
to CAD model of part being simulated at
a similar position.
- adjust the parameters of the deposition Provides a pragmatic calibration with
model until ´best fit´ of tubes is reached. standardized test geometry

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Calibration of E-Coat Simulation Parameters:
(3) Lab Measurements with Test Box and Plain sheets

Box is closed
on bottom
and side.
Top is above
electrolyte level
Calibration of E-Coat Simulation Parameters:
(3) Lab Measurements with Test Box (Medium Throw Power)
100V 200V

Measurement

Measurement
Calibration of E-Coat Simulation Parameters
(3) Lab Measurements with Test Box (Good Throw Power)
100V 200V

Measurement

Measurement
Application of STAR-CCM+ E-Coat Simulation:
Thickness Building over Time

15
Application of STAR-CCM+ E-Coat Simulation:
Visualization of Thickness in Cavities

Video Page 16
Application of STAR-CCM+ E-coat Simulation:
Example of Good Throw Power

17
Application of STAR-CCM+ E-coat Simulation:
Example of Medium Throw Power

18
Application of STAR-CCM+ E-coat Simulation:
Example of Poor Throw Power

19
Application of STAR-CCM+ E-coat Simulation:
Comparison of different Throw Power Capabilities

Good

Medium Poor

20
Application of STAR-CCM+ E-coat Simulation:
Comparison of different Throw Power Capabilities

Geometrical Variation Good

will be necessary

Medium Poor

21
Application of STAR-CCM+ E-coat Simulation:
Evaluation of Gemetrical Variation (for better Corrosion Protection)

Holes have influence on E-Coat thickness

Bigger Diameter or more holes improve corrosion protection
Simulation of Dipping in: (1sec=1h on 32 CPU, 8 Cores/CPU)
Remaining Air Bubbles Avoid E-Coat Film Building
(Red = Trapped Air Bubbles)

Video
23
Simulation of Dipping in (1sec=1h on 32 CPU, 8 Cores/CPU)
Remaining Air Bubbles Avoid E-Coat Film Building

24
Simulation of Dipping in: (1sec=1h on 32 CPU, 8 Cores/CPU)
Visualization of Trapped Air

Video
25
Simulation of Dipping in (1sec=1h on 32 CPU, 8 Cores/CPU)
Remaining Air Bubbles Avoid E-Coat Film Building

26
Simulation of Dipping in:
Positioning of additional Bleeding Holes

Final Position in E-coating should

be without air bubbles.
Simulation gives information for
positioning of bleeding holes.

27
Simulation of Dipping in:
Quick optimization check by adding holes and continuing simulation
(Red = Trapped Air Bubbles)

Holes added at t = 25s

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Simulation of Dipping out:
(Remaining Ponds Contaminate Next Dipping Process Step)
(Blue = Trapped Dipping Liquid)

Video
29
Simulation of Dipping out:(1sec=1h on 32 CPU, 8 Cores/CPU)
(Remaining Ponds Contaminate Next Dipping Process Step)

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Simulation of Dipping out: (1sec=1h on 32 CPU, 8 Cores/CPU)
Calculation of Drainage Time

31
Video
Simulation of Dipping out:
Quick optimization check by adding holes and continuing simulation:
(Blue = Residual ponds)

32
Simulation of Dipping out:
Quick optimization check by adding holes and continuing simulation:
(Blue = Residual ponds)

Holes added at t = 20s

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Details of Dipping out Simulation:
Remaining Ponds Contaminate next Dipping Process Step

34
Virtual Manufacturing

Clients E-Coat Simulation

to Improve
Corrosion Protection

Flow Fronts in
Fiber Reinforced Plastic
Prospects Manufacturing(SMC)

Corrosion Test Chamber

Simulation (Multiphysics
without Chemical Reactions)

Industry
Additive
Awareness Manufacturing (AM)

Exploration Pilot Market Ready