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Sebastian Katona, Michael Koch, Tobias C. Spruegel and Sandro Wartzack



Within today’s product development process, various FE-simulations (finite element) for the functional validation of the desired characteristics are made to avoid expensive testing with real components. Those simulations are performed with great effort for discretization, use of simulations conditions, like taking different non-linearities (i.e., material behavior, etc.) into account, to create meaningful results. Despite knowing the effects of deformations occurring during the production processes, always the non-deformed design model of a CAD-system (computer aided design) is used for the FE-simulations. It seems rather doubtful that further refinement of simulation methods makes sense, if the real manufactured geometry of the component is not considered for in the simulation. For an efficient exploit of the potential of simulation methods, an approach has been developed which offers a geometry model for simulation based on the existing CAD-model but with integrated production deviations as soon as a first prototype is at hand by adapting the FE-mesh to the real, 3D surface detected geometry.


FEA (finite element analysis), preprocessing, simulation, 3D surface detection, RE (reverse engineering)

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