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VISUALISATION OF SURFACE DEFECTS IN SHEET METAL PANELS

Application of implicit and explicit solvers has proven the usefulness of simulation to predict splits and wrinkles. The challenge now lies in extending the use of simulation to analyse aspects of panel quality. Chief amongst these are defects due to small deviations from the as-designed surface. These defects can be seen around formed areas within largely flat panels. The defects can be obvious to the naked eye even when less than 30μm deep; simulation involves the full sequence of forming operations including springback. While these calculations can predict displacements, they cannot reveal the visual impact of the defect. This paper describes a method to visualise surface defects using a combination of LS-DYNA and LS-NIKE3D together with the ray-tracing code RADIANCE. Results from initial investigations are presented.