GENERATING HYBRID GEOMETRY MODELS FOR MORE PRECISE SIMULATIONS BY COMBINING PARAMETRIC CAD-MODELS WITH 3D SURFACE SCANNED GEOMETRY INSERTS

In general, every component shows differences to its ideal geometry of the designed CAD-model, i.e. due to deformations in the production process. Despite knowing the effects of deformations, the product developer always uses the ideal, non-deformed design model of the CAD-system for FE-simulations of a component. It seems rather doubtful that further refinement of simulation methods (e.g. using different non-linearities) makes sense, if the real manufactured geometry of the component is not considered for in the simulation process. Therefore, this paper describes an approach to use hybrid geometry models for simulations, which are mostly built of the parametric CAD-model, but areas with large deviations are substituted with surface reconstructed scan-inserts based on 3d surface scanned data, reconstructed to NURBS-patches. This procedure allows a more precise simulation as it considers deviations by minimizing the amount of data and the time for model preparation.