Digital cavity preservation simulation (CP simulation)
Our simulation department can secure the application of cavity preservation (CP) at an early stage of development, based on 3D CAD design data.
The advantages of digital simulation:
- We develop your jet heads.
- We optimize material consumption even before the prototype is built or production starts.
- We can investigate the effects of design changes on the waxing process.
- You can secure your process planning by simulation and reduce or avoid the precipitation of overspray at undesired places.
Production process of the digital CP simulation
Step 1: Simulation and design
The CP simulation is based on a CFD/flow simulation of the entire application process. In addition to the simulation of the wax application, it also includes further process steps, such as the heating up of the car body by an oven or infrared radiation, calculating the internal jet flow or the propagation of emissions within the entire vehicle.
During the simulation we can take all process parameters such as times, tipping angle and direction, temperatures, application pressure, etc. into account. This enables us to map your entire waxing process.
For an optimal coating result, the correct design of the jets, the distribution of the material in the component and a consideration of the material properties are crucial – our CP simulation takes all three factors into account. We can use existing jet data, optimise them if necessary or develop new ones for you.
Step 2: Securing and optimization
Our CP simulation can check and secure corrosion protection in planned CP processes or in existing production processes and optimise the coating quality. By digitally mapping all process parameters, a wide variety of application variants can be simulated very easily and quickly and the optimal line setting determined.
Step 3: Avoidance of overspray and contamination
Overspray refers to the spray mist generated outside the component or area to be applied when applying CP. If the resulting overspray settles on surfaces that need to be as clean as possible for further processing, these may have to be cleaned at great expense. With our CP simulations we are able to identify the causes of annoying overspray and reduce or even completely avoid it by targeted design of the jet heads. Contamination by cavity preservation is caused, for example, by excessive dripping from the car body. We can use our CP simulation to investigate the causes of the dripping and derive ways of avoiding or reducing it.
Step 4: Feasibility and achievability analysis
With the CP simulation we have developed, we can virtually examine individual components or even the complete vehicle at an early stage of development using 3D CAD data. Especially with complex components and geometries, simulation provides important information on the expected coating result.
Step 5: Technical design advice
Our calculation shows that a complete coating is not possible (e.g. using the existing set points or jets or due to other restrictions). We can show you possible solutions early in the development process, for new developments and for existing geometries in production vehicles.
Step 6: Jet heads/spray jets
One of the most important elements of wax application in vehicles are the CP jets that are used. They have to be designed in such a way that all areas that are to be protected are reached and that as little overspray or contamination as possible occurs.
Using CP simulation, we can already optimise these jets to an extent in the development phase which ensures that a high coating quality is achieved with minimum material input and minimal contamination.
The video shows the application process on a component as it occurs in an industrial environment. First, wax is sprayed through the jets, which are inserted through holes in the component. In the further process, the component (vehicle) is tilted so that folds at the bottom can be tapered and excess material can flow out. The result is a component that is completely coated in the folds.