FE-simulation method for a flexible clamping technology for Body in White assemblies

Due to the growing number of derivatives and the rising demand for electric vehicles, flexibility in automotive production becomes more and more important. The use of running clamping technology enables flexible clamping of remote laser welded Body in White assemblies. Although the process design for this new technology is challenging, no digital process design method is available. The finite element (FE) process simulation offers an opportunity to reduce time- and cost-intensive experiments during the part and process design phase. In this article, a new and comprehensive FE-simulation method for running clamping technology is presented. The clamping simulation is validated with experiments using L-specimens. Therefore, the clamping forces required to close the gap between part flanges are evaluated. Further, the clamping and mechanical joining simulation of a Body in White assembly is validated by comparing the resultant joint gaps. The capability of the simulation method is demonstrated by a numerical investigation of the influences of process parameters on the resultant joint gaps. The parameters that were investigated are geometrical inaccuracies, applied clamping force and design of the clamping device. The results obtained indicate that higher geometrical inaccuracies of parts can be accepted when using clamping devices with clamping supports.