Fit and finish of vehicle split-lines is one important contributor to the final Perceived Quality (PQ) of the product. To achieve high PQ of split-lines, effects of geometrical variation has to be considered.

In early phases of the development chain the geometry models used for simulation and visualization have low level of detail. This limits the possibility to perform certain simulations that rely on a more complete detailed design. Consequently, alternative methods have to be considered to predict and simulate possible outcome in early phases concerning PQ issues.

This paper proposes how an existing non-FEA-based deformation method can support virtual assessment of the PQ of split-lines in early phases. The method is based on mesh morphing and has been implemented in a CAT-tool (Computer-Aided Tolerancing). Its strength lies in the simplicity of generating deformed shapes. The paper specifically focuses on how available knowledge regarding issues from previous projects can be used as input to the method, to predict part deviation and part behavior. The paper further presents industrial examples where the method has been applied. The results show that the proposed technique can be used as a complement to other simulation tools in early phases, where low level of detail on geometries limits the possibility to perform FEA (Finite Element Analysis) based simulations.

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