intelligent electrochemical racking up the profits
TRANSCRIPT
![Page 1: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/1.jpg)
Intelligent electrochemical process solutions
Racking up the profits Leveraging plating simulation technology to
optimize rack and tooling design
Dr. Alan Rose ([email protected]) 770-328-1346
![Page 2: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/2.jpg)
Where Technique Meets Technology
![Page 3: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/3.jpg)
Smart Manufacturing
![Page 4: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/4.jpg)
Smart Manufacturing
• Smart Manufacturing is revolutionizing process and product innovation, productivity and resource efficiency by combining the physical and virtual worlds.
“In short, at the company and plant level, we
are seeing tremendous improvement potentials in productivity and efficiency thanks to software
technology.” Helmuth Ludwig, CEO Siemens
![Page 5: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/5.jpg)
Moore’s Law and Computing Power
The law is named after Intel co-founder Gordon E. Moore, who described the trend in his 1965 paper. The paper noted that the number of components in integrated circuits had doubled every year from the invention of the integrated circuit in 1958 until 1965 and predicted that the trend would continue "for at least ten years". The period often quoted as "18 months" is due to David House, an Intel executive.
![Page 6: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/6.jpg)
Everyday Engineering Analysis…
• Stress analysis • Thermal analysis • Fluid flow • Seismic • Crash dynamics… simulate or trial & error?
Why not surface finishing?
![Page 7: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/7.jpg)
Technique – honing your skill
Experience, Know-how, Empirical
![Page 8: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/8.jpg)
Technology – upfront analysis
First four flights Kitty Hawk 17 December 1903 – from concept to flight 5 years
Design & simulation tools
Stress the
concept
![Page 9: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/9.jpg)
How do Surface Finishing Manufacturing Executives Make & Qualify Investment Decisions?
In 2012 we surveyed 9000 individuals connected to the SF sector, of which 300 (and growing) responded in full
(3.3%).
CAE Awareness in Surface Finishing
![Page 10: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/10.jpg)
Who’s viewpoint
32.7%
2.7%
26.4%
50.5%
3.2%
ExecutiveFinancialManagerialTechnicalAdministrative
![Page 11: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/11.jpg)
Challenges
Rate the business challenges Exec Tech OEM Supplier
Costs 1 2 3 1 Productivity 2 3 2 2 Capacity Quality 3 1 1 3 Regs compliance Project lead times Supplier capability
![Page 12: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/12.jpg)
Threats
Rate the threats Exec Tech OEM Supplier
Competition domestic Competition international 3 3 3
Lack of trained staff 1 1 1 1
Lack of resources & investment 3 Regulations 2 2 2 2
![Page 13: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/13.jpg)
Costs
Rank the costs Exec Tech OEM Supplier
Labor 2 3 2
Scrap, rework 3 3 3
Energy 3
Materials, commodities 1 1 1 1
Plant, equipment 2
Transportation
Environmental 3 2 2
![Page 14: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/14.jpg)
How do you Quantify the Impact of Technical Decisions on Business Investments?
• Business Analytics/Statistics, • Industry Guidelines/Practices, • Proprietary Guidelines/Practices, • Activity based costing (ABC) tools (e.g. Plato ), • Engineering Simulation Tools (e.g.
PlatingMaster, Plato, FlexTime, FEA, CFD)
![Page 15: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/15.jpg)
Tools to assess business decisions
0% 10% 20% 30% 40%
Engineeringsimulation
Activity basedcosting
Proprietaryguidelines
Industry guidelines
Business analytics
![Page 16: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/16.jpg)
What are the limits of traditional rule of thumb methods in process design and improvement decision making?
![Page 17: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/17.jpg)
What can we learn from a virtual plating line?
A Virtual twin
![Page 18: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/18.jpg)
Quality
Compliance
Cost
Productivity
Q-specs defined to ensure in-field service – no corrosion,
Up-front plating manufacture simulation shows part will fail, due to under-spec chrome thickness
Rapid PI calculation in design studio, immediately identifies costly Design-Manufacture issue
Plateability Index (PI) mapping
EPA/OSHA Eliminate hazardous materials. Lab. characterization of proposed coating=> Simulation quantifies technical risk of scale-up
Optimize rack configuration and tooling for maximum in-spec productivity
Plating Challenges
![Page 19: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/19.jpg)
Productivty - Rack optimization – starting point
• Under spec at points on both surround grills on physical tests • Simulations follows very closely - maximum deviation is 3 micron • Plating time is fixed
P3
P2 P4
P1
Plant data
![Page 20: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/20.jpg)
Rack optimization – comparison (v5)
Original case Optimization case
Out of spec region
![Page 21: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/21.jpg)
Production result
All P-points above specification Tighter tolerance
• Less waste • In-spec • Higher
throughput
Plant data
![Page 22: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/22.jpg)
Model Predict Optimize
Modeling Process
![Page 23: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/23.jpg)
-23-
Technology – key ingredients
Physico-chemical data gathering
Infrastructure configuration (CAD)
Part/structure model (CAD)
Process parameters Imposed potential or current, plating times,
etc.
Elsyca proprietary m
eshing and solving (FEM)
Simulated current density distribution and
deposited layer thickness
![Page 24: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/24.jpg)
Gerd Reineck, TRW Robrecht Belis, Elsyca
Rack Optimiation of VW Steering Wheel Bezel
![Page 25: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/25.jpg)
Automotive trends for interior parts
25
simple geometries
complex geometries
![Page 26: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/26.jpg)
Comparison of plating processes
26
Conventional electroplating process: thickness of visible internal surface of the parts not successful – Faraday cage numbers of parts are limited color deviation on the bezel due to thickness variations high scrap rate
Electroplating process with auxiliary anodes: thickness all internal surface within customer specification reduction of scrap rate increasing of numbers of parts on the racks uniform color of all areas on the bezel
Faraday cage - poor macro throwing power
![Page 27: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/27.jpg)
Project description
27
Project description (outsourced to Elsyca) − Chrome plate steering wheel bezel − Define optimal rack load/part orientation − Define optimal process conditions − Design rack − Identify potential suppliers
Challenges − Geometry with recessed area − Geometry with sharp edges − No design changes allowed − Very short time window (5-6 weeks)
![Page 28: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/28.jpg)
Project steps
• Requirement definition • ‘As-is’ simulation • Optimization based on simulations • Design auxiliary anodes • Design technical drawing rack • Build physical rack • First prototype run • Electroplating in practice • Further optimization by simulation/trial • Performance auxiliary anodes
28
![Page 29: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/29.jpg)
29
Requirements - ‘As-is’ simulation
Requirement of … Thickness
… copper > 20 µm
… nickel > 10 µm
… chrome 0,3 µm
Requirements by customer
Measuring points according to drawing
Measuring point
1 2 3
copper 13 6 10
nickel 5 2 3
chrome 0.19 0.08 0.13
Parts were not accepted by customer
Complete absence of Cr coverage
Average simulated thickness by Elsyca
![Page 30: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/30.jpg)
30
Optimization based on simulations
Design and validate current robbers Rack load and part orientation Process parameter
0 2 4 6 8 10 12 14 16 18 20 22
eeee i (A/dm2)
![Page 31: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/31.jpg)
31
Design auxiliary anodes
Complete absence of Cr coverage
with auxiliary anode
without auxiliary anode
Part entirely with specification
4 auxiliary anodes – platinized Titanium 3 x 3 mm diameter pens 1 x 6 mm diameter pen
![Page 32: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/32.jpg)
32
Design technical drawing rack
Anode frame
Cathode frame The frames are isolated to prevent short circuit
![Page 33: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/33.jpg)
33
Build physical rack
Rack production from builder Leukel, Hünstetten, Germany
Rack preparation based on simulation for the first trial Coated rack Rack manufacturer LEUKEL has in the complicated processing of racks with auxiliary anodes sufficient experience
![Page 34: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/34.jpg)
First prototype run • All parts are within specification • Time from start to first production run was 5 weeks
• Auxiliary anodes are very powerful, but
– Requires excellent rack production (exact dimensions as simulation)
– Requires more care to load/unload the part – See next slide
• Iteration to further improve production robustness on auxiliary anode design
34
![Page 35: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/35.jpg)
35
Electroplating in practice
distance o.k.
distance not o.k..
burn marks
![Page 36: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/36.jpg)
36
Further optimization by simulation/trial Variances 4 auxiliary anodes – platinized Titanium
3 x 3 mm diameter pens 1 x 6 mm diameter pen
1 auxiliary anodes (rectangular) 12,7 x 3,2 mm
5 auxiliary anodes – platinized Titanium 3 x 3 mm diameter pens
![Page 37: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/37.jpg)
37
Performance auxiliary anodes
Variances
30 27 2421181512 9 6 3 0
i (A/dm2)
30 27 2421181512 9 6 3 0
i (A/dm2)
![Page 38: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/38.jpg)
38
Results of production
Electroplating with auxiliary anodes
Thickness entirely according to customer specification
Measuring point
Cu 20 µm
Ni 10 µm
Cr 0,3 µm
1 21-30 11-15 0.32-0,50
2 22-28 12-15 0,35-0,52
3 21-32 11-16 0.30-0,50
![Page 39: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/39.jpg)
Summary
39
Plastic components with complex shapes could be metalized this implies more flexibility for the designers
Worldwide one of the very few examples of a decorative bezel using auxiliary anodes
Overall aims of this technologically challenging production process were met using auxiliary anodes
Simulations provided all required information to ‘produce-right-first-time’
Very short time windows are challenging, but not impossible
Results from the overall research were successful
![Page 40: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/40.jpg)
Is it catching on?
• GM14668 • Ford Engineering Design Rule • Several large platers implemented across
the board
-40-
![Page 41: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/41.jpg)
-41-
Conclusions
• Engineering simulation is more flexible, predicting ahead – empirical relies on the past and experience
• Awareness and use of prediction tools in Surface Finishing is very low compared to other sectors
• OEMs recognizing value and beginning to call out in SORs
![Page 42: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/42.jpg)
Origin of the Phrase “Rules of Thumb”
One origin of the phrase “rules of thumb” is not flattering… The exact origin of the phrase is uncertain. The earliest citation comes from J. Durham’s Heaven upon Earth, 1685, ii. 217: "Many profess Christians are like to foolish builders, who build by guess, and by rule of thumb."[1]
![Page 43: Intelligent electrochemical Racking up the profits](https://reader033.vdocuments.site/reader033/viewer/2022061102/629d3cf700fdfb0f7423a220/html5/thumbnails/43.jpg)
Don’t be Distracted by the Rearview
Thank You. Questions?