Virtual Reality (VR) in engineering is often associated with applications in product evaluation in terms of mountability, maintainability, ergonomics or in industrial engineering. Nevertheless, several VR applications have been established in recent years that deal with manufacturing processes.

1. Whitepaper
Virtual Reality in Manufacturing
Processes
Applications, Challenges, Results
© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Dr.-Ing. Dipl.-Kfm. Christoph Runde
Virtual Dimension Center (VDC) Fellbach
Auberlenstr. 13
70736 Fellbach
www.vdc-fellbach.de
ϭ
Applications, Challenges, Results

2. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Environment Virtual Reality – Manufacturing processes
Virtual Reality (VR) in Engineering often associated with mountability,
maintainability, ergonomics, industrial engineering
Recent years: several VR projects in manufacturing applications
Basics
2
Image: Main groups of manufacturing processes
according to DIN 8580
Manufacturingprocesses
Primary
Forming
Forming Separating Joining Coating
Change
Material
Charact.

3. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Environment Virtual Reality – Manufacturing processes
Design of manufacturing processes: often a
spatially complex task
Thereby VR can basically be applied effectively
VR applications: often post-processing of data
from physical simulation, such as
Computational Fluid Dynamics (CFD) or Finite
Basics
3
Computational Fluid Dynamics (CFD) or Finite
Element Analysis (FEM)
Strong use of interaction metaphors
Support of local or distributed cooperative work
with VR
Augmented reality (AR) for model validation
Virtual machining center

4. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Applied VR techniques
False color representation: a physical
quantity (such as temperature, mechanical
stress) is visualized via color coding.
Samples: the viewer can use a measuring
sensor to display measured values of the
model. The sensor can be variable
Image: Fraunhofer IPA
Display level of
cleanliness through false
colors
ZusammenfassungBasics
4
model. The sensor can be variable
regarding the measured quantity. The
sample may also be a source of particles
(in a flow field).
Sections: the 3D model is “cutted/
clipped” in order to visualize the areas of
interest of the specific viewer.
Image: Fraunhofer IPA
Image: Visenso
Sample for coating
thickness measurement
Cut through cast part

5. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Applied VR techniques
Time-lapse, slow motion: dynamic animation
(recognizing temporal relationships) can be
accelerated, slowed down and frozen.
Reinforcement: physical quantity (such as layer
thickness, deviation in the case of oscillation) is
reinforced in a way that it “becomes visible”.
Image: Visenso
Animation
flow simulation
Basics
5
Comparative presentation: alternative production
processes (e.g. due to other process parameters
such as feed rate) are shown simultaneously in
order to be able to identify both the absolute values
of the individual processes and differences between
them.
Subtractive presentation: only the difference
between two process alternatives is displayed. This
makes process differences even easier to identify.
Image: Fraunhofer IPA
Image: Visenso
Reinforcement: display
layer thickness varnish
Comparing representation,
differentiated display

6. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Applied VR techniques
Selective representation based on values: only
model areas whose elements have measured
values in a specified area are displayed. This
allows problem areas to be extracted very quickly.
Superposition: different simulation results or a
test part and a simulation result are
Image: Fraunhofer IPA
Selective representation
based on value range
Basics
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test part and a simulation result are
superimposed. If the simulated process results are
superimposed with the method actually used,
deviations indicate optimization potential of the
simulation model or qualitative fluctuations of the
procedure.
Inline analysis with AR: furthermore, process
parameters and measured values can be
graphically overlaid on a workpiece, possibly even
during the production process.
Image: Project Arvika
Image: Nee
Superimposition
simulation
on trial
Superimposition
online-process data on
workpiece

7. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Primary forming
Manufacturing of a solid body out of
shapeless material by creating a cohesion;
in this case, the material properties of the
workpiece appear and can be determined
Amongst others all casting and separation
techniques are manufacturing processes of
Image: Visenso
Casting simulation
(flow, temperature)
Primary Forming
7
techniques are manufacturing processes of
primary forming
VR applications:
o Process analysis
o Component analysis
Image: Visenso
Image: Visenso
Casting simulation,
filling level
Casting simulation
(flow, temperature)

8. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Primary forming: Casting
Simulation objective: to achieve the desired
component properties (strength, tolerances,
prevention of cavities) in the case of an
optimal casting process (process reliability,
process speed).
VR applications for casting simulation show
Image: Visenso
Casting simulation:
flow, temperature
Primary Forming
8
VR applications for casting simulation show
the casting process itself and the result
Viewer looks at melt flow in the course of
time and temperature with or without shape
Temperature profile during cooling
Back off areas
Take samples
Put particle sources
Image: Visenso
Image: Visenso
Casting simulation:
cooling phase
Cast part:
detection of cavities

9. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Primary forming: Casting – Mechanical engineering
Checking functionality machine
Digital mock-up
Kinematics
Physics, control technology
Process simulators
Image: Visenso
Diecasting mould
Primary Forming
9
Image: Sun
Image: Fraunhofer IPA
Pressure die mould
Continuous casting plant

10. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Primary forming: Casting – Mechanical engineering
Functionality casting tool
Kinematics
Collisions/
clearance
Primary Forming
10
Diecasting mould
Image: Visenso GmbH

11. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Forming
Manufacturing through plastic changing the shape of
a solid body
Maintaining mass and cohesion
Pressure forming (such as rolling, closed-die forming,
extrusion) and deep drawing rank among forming
processes
Simulation goal: achieve the desired component
Image: Visenso
Deep drawing simulation:
engine hood
Forming
11
Simulation goal: achieve the desired component
properties (such as geometry, tolerances, thickness,
strength) in the case of an optimal forming process
(such as process reliability, process speed)
Analysis of the forming process in the course of time
Material strain/ stress
Temperature developments
Workpiece as reshaping result itself
Image: Visenso
Image: RWTH Aachen
Simulation extrusion
Simulation closed-die
forming (forging)

12. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Forming: Deep drawing – Mechanical engineering
Checking functionality machine
Digital mock-up
Kinematics
Physics, control technology
Process simulators
Image: Visenso
Deep drawing press
Forming
12
Image: Visenso
Image: Fraunhofer IPA
Press mould
Rollers steel mill

13. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Forming: Deep drawing – Mechanical engineering
Functionality of molding tool
Loads
Kinematics
Forming
13
Deep drawing press with
engine hood
Image: Visenso GmbH

14. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Separating
Manufacture by reducing (partially or
completely) the cohesion of bodies
Amongst others drilling, milling,
disassembly and cleaning rank among the
separative manufacturing processes
Interactively analyze the results of a
Image: Visenso
Simulation drilling
Separating
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Interactively analyze the results of a
process simulation on the workpiece
Evaluate machine tool programming:
Virtual Machining Image: Visenso
Image: Nee
Simulation miling
Fading online-process
data on workpiece

15. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Separating: Machining
Optimization of machining processes:
detailed knowledge of processes is
necessary
Simulation of the chip formation process:
expand understanding of the thermal and
mechanical loads of tools and workpieces
Simultaneous 3D
illustration and
Separating
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mechanical loads of tools and workpieces
Considerations regarding temperature and
voltage path
Also the chip as a geometrical structure
and its physical properties are illustrated.
Interesting aspects are temperature
development, distribution and dissipation
Avoid component warpage
Image: Visenso
Image: Visenso
illustration and
numeric information
Simulation milling

16. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Separating: Disassembly
Virtual environments with collision
detection and sliding simulation are used
in the investigation of assembly and
disassembly
For this purpose, the position and
orientation of a component which has to
Image: ESI – IC.IDO
Assembly inspection with
2-handed interaction VR
Separating
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orientation of a component which has to
be installed/ disassembled is specified with
a spatial input system
Virtually occurring collision forces are
displayed
Image: ESI – IC.IDO
Image: Haption
Disassembly
examination in VR
Tactile supported
disassembly examination

17. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Separating: Cleaning
• Focus on accessibility studies
• Ray tracing algorithms: all relevant component
surfaces detected by the cleaning agent?
• Color marking, cuts and selection
• Quickly identify critical areas
• Technological proximity to coating simulation
Image: Fraunhofer IPA
Cleaning simulation
Separating
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• Technological proximity to coating simulation
and raytracing
• Simulation of dry-ice blasting: gentle blasting
media deflection by means of an additional
compressed air flow; improved ablation
performance
• Development nozzle (injector bend), rapid
prototyping, evaluation of radiance trial
simulation
Image: Fraunhofer IPA
Image: Fraunhofer IPA
Cleaning simulation
Cleaning simulation

18. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Joining: Welding
Permanently applied joining or other combining
procedures of two or more work pieces of
geometrically determined solid form or
shapeless material
In doing so cohesion is created locally and
increased as a whole
Image: ESI
ESI for AREVA:
Simulation crack path in
welding process
Joining
18
All mounting topics as well as welding
Comparative welding spot simulation with
different parameter sets (animated)
Offline programming of robots: safe and
without occupying the real cell
AR inline support welding process: correctly
positioned and context-related superimposition
of process variables in the real welding glasses:
corrections during process Image: VDC
Robot - welding cell
Image: Visenso
Visualization simulated
welding spots

19. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Coating
Manufacture by applying a firmly adherent
layer of shapeless material to a workpiece
The decisive factor is the immediately prior to
coating state of the coating material
Varnishing rank among the manufacturing
processes of coating
Image: Fraunhofer IPA
Varnishing simulation:
robot trajectories
Coating
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processes of coating
The aim of the simulation is to achieve the
desired properties (such as layer thickness) in
the case of an optimal varnishing process
(such as process reliability, process speed, use
of resources)
VR applications for varnishing simulation aim
at the analysis of the varnishing process itself,
the result and the training of the varnishing
process
Image: SimSpray
Image: Fraunhofer IPA
Varnishing trainer
SimSpray
Varnishing simulation:
sample

20. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Coating: Varnishing
Analysis of the 3D model grid values
Virtual samples
Selective area display: show only these areas in which
elements have certain simulation result values (here:
paint layer thicknesses between 21 and 42 µm)
Spatial area display: according to spatial
considerations: area selection via cubes (left window
Image: Fraunhofer IPA
Varnishing simulation:
grid analysis
Coating
20
considerations: area selection via cubes (left window
in image below)
Enclosed model area: right window (in image below)
Upper right window: reinforced representation
Bottom right window: top view, aligned in the
coordinate system
Selection: zooming on the entire screen
Image: Fraunhofer IPA
Image: Fraunhofer IPA
Varnishing simulation:
selective display
Varnishing simulation:
selection of area

21. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Change material characteristics
Manufacture by changing the material´s
properties of a workpiece
Through changes in the submicroscopic or
atomic area, e.g. by diffusion of atoms,
generation and movement of dislocations in the
atomic lattice, chemical reactions
Image: RWTH Aachen
Forged part
Change Material
Characteristics
21
Manufacturing process: Consolidate by forming
and sintering
Consolidate by forming: same VR tools as for
forming
VR tools specially for sintering: analysis of the
sintering process and the workpiece
Workpiece sections/ cuts through workpiece:
clear view on workpiece properties (such as
density, strength)
Image: Fraunhofer ITWM
Math2Market
Image: Fraunhofer ITWM
Math2Market
Sinter material
Sinter material

22. Separating Change Material
Characteristics
Basics Primary Forming Forming Joining Coating Summary
Summary
Virtual reality techniques are already used
today for the analysis and design of
numerous manufacturing processes
In some application areas, such as
casting, the use of VR is well-developed
Other topics: general need to catch up
Image: VDC
View in virtual machining
center
Summary
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Other topics: general need to catch up
Research has shown that identified VR
applications do not even represent half of
all possible manufacturing processes
At the same time, it became apparent
that in a specific case often only a small
part of the possible applicable VR
technologies is used. Often it would be
worth it to think outside the box
Image: VDC
Image: VDC
View on virtual control
View on injection
moulding machine

23. ESI – IC.IDO: IDO.Explore
http://www.icido.de/de/Produkte/VDP/IDO_Explore.html, abgerufen 2011
Fraunhofer IPA: Fraunhofer Institut für Produktionstechnik und
Automatisierung (IPA): Fabrikplanung und Produktionsoptimierung,
http://www.ipa.fraunhofer.de/index.php?id=79, abgerufen 2006
Fraunhofer IPA: Fraunhofer Institut für Produktionstechnik und
Automatisierung (IPA): waterjet cleaning, Teilereinigung 5.3,
http://www.youtube.com/watch?v=v-wRifXED5Q, abgerufen am 12.4.2012
Fraunhofer IPA: Fraunhofer Institut für Produktionstechnik und
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DIN 8580: Norm DIN 8580 2003-09 Fertigungsverfahren – Begriffe,
Einteilung
RWTH Aachen: Rheinisch-Westfälische Technische Hochschule (RWTH)
Aachen: Visualization of Metal Forming Process, http://www.rz.rwth-
aachen.de/aw/cms/rz/Themen/Virtuelle_Realitaet/research/projects/mechani
cal_engineering/~plv/visualization_of_metal_forming_processes/?lang=de,
23
Fraunhofer IPA: Fraunhofer Institut für Produktionstechnik und
Automatisierung (IPA): Lackiertechnik,
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abgerufen am 12.4.2012

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© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Virtual Dimension Center (VDC) Fellbach
Auberlenstraße 13
70736 Fellbach
www.vdc-fellbach.de
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