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Surapaneni, Sreekanth
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Automotive Vehicle Body Temperature Prediction in a Paint Oven

Chrysler Group LLC-Yu Hsien Wu, Sreekanth Surapaneni, Kumar Srinivasan, Paul Stibich
Published 2014-04-01 by SAE International in United States
Automotive vehicle body electrophoretic (e-coat) and paint application has a high degree of complexity and expense in vehicle assembly. These steps involve coating and painting the vehicle body. Each step has multiple coatings and a curing process of the body in an oven. Two types of heating methods, radiation and convection, are used in the ovens to cure coatings and paints during the process. During heating stage in the oven, the vehicle body has large thermal stresses due to thermal expansion. These stresses may cause permanent deformation and weld/joint failure. Body panel deformation and joint failure can be predicted by using structural analysis with component surface temperature distribution. The prediction will avoid late and costly changes to the vehicle design. The temperature profiles on the vehicle components are the key boundary conditions used to perform structure analysis. This paper presents an efficient method to predict vehicle body temperature profiles as the vehicle pass through the radiant section of an e-coat and/or paint oven. Transient analysis coupled with geometry movement is used to predict the vehicle…
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A Technique to Predict Thermal Buckling in Automotive Body Panels by Coupling Heat Transfer and Structural Analysis

Chrysler Group LLC-Paul R. Stibich, Yu Hsien Wu, Weidong Zhang, Michao Guo, Kumar Srinivasan, Sreekanth Surapaneni
Published 2014-04-01 by SAE International in United States
This paper describes a comprehensive methodology for the simulation of vehicle body panel buckling in an electrophoretic coat (electro-coat or e-coat) and/or paint oven environment. The simulation couples computational heat transfer analysis and structural analysis. Heat transfer analysis is used to predict temperature distribution throughout a vehicle body in curing ovens. The vehicle body temperature profile from the heat transfer analysis is applied as an input for a structural analysis to predict buckling. This study is focused on the radiant section of the curing ovens. The radiant section of the oven has the largest temperature gradients within the body structure. This methodology couples a fully transient thermal analysis to simulate the structure through the electro-coat and paint curing environments with a structural, buckling analysis. The ability to predict the buckling phenomenon using a virtual simulation will reduce the risk of late production changes to the vehicle class “A” surfaces.
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CFD Analysis of Automotive Bodies in Static Pressure Gradients

Chrysler Group LLC-Mark E. Gleason, Todd Lounsberry, Khaled Sbeih, Sreekanth Surapaneni
Published 2014-04-01 by SAE International in United States
Recently, the Two-Measurement correction method that yields a wake distortion adjustment for open jet wind tunnels has shown promise of being able to adjust for many of the effects of non-ideal static pressure gradients on bluff automotive bodies. Utilization of this adjustment has shown that a consistent drag results when the vehicle is subjected to the various gradients generated in open jet wind tunnels. What has been lacking is whether this consistent result is independent of the other tunnel interference effects. The studies presented here are intended to fill that gap and add more realistic model and wind tunnel conditions to the evaluations of the performance of the two-measurement technique. The subject CFD studies are designed to greatly reduce all wind tunnel interference effects except for the variation of the non-linear static pressure gradients. A zero gradient condition is generated by simulating a solid wall test section with a blockage ratio of 0.1%. The non-linear gradients are simulated using a semi-open jet test section with a very large 40 square meter nozzle exit and a…
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