AutoForm Assembly 26 – New Capabilities for Faster and More Accurate BiW Assembly Process Validation

AutoForm Assembly R26 introduces a new arc welding model for the simulation of MIG/MAG welding processes. Compared to laser welding, MIG/MAG welding generates higher heat input, resulting in a larger heat-affected zone and increased thermal distortion, which can significantly affect dimensional accuracy. Using key process parameters, the software automatically determines the effective heat input and resulting thermal loads, enabling a realistic prediction of welding-induced dimensional deviations. This new software capability provides deeper insights into the effects of welding on dimensional behavior, supports optimized joining process design, and helps engineers make confident decisions earlier in the development cycle.

This software release supports efficient use of scanned subassemblies. In many cases, users need to design assembly processes that include subassemblies as components. Their primary focus is on the process being developed, while the subassemblies are treated as inputs. In the later stages of development, once prototypes of these subassemblies become available, users can improve dimensional accuracy by incorporating their measured geometry into the assembly process. With AutoForm Assembly R26, measured subassembly data can be directly integrated into the simulation, enabling more realistic and reliable results.

AutoForm’s assembly simulation supports users in validating dimensional accuracy against clearly defined engineering requirements specified by GD&T. With AutoForm Assembly R26, GD&T information from CAD becomes an integral part of the simulation workflow. GD&T definitions are automatically interpreted and used throughout setup and evaluation, preserving the original design intent from CAD. This establishes a direct link between engineering requirements, assembly validation, and quality assessment, enabling faster and more consistent validation with greater confidence in engineering decisions. 

In addition, AutoForm Assembly R26 introduces new options for mirroring and translation of asm files, accelerating simulation setup and increasing engineering efficiency. The software also enables users to efficiently reuse and adapt existing subassemblies for new vehicle projects. Users can import an existing subassembly into the new vehicle environment and position it accordingly. The software automatically updates the subassembly definition, ensuring rapid and efficient adaptation to new vehicle design requirements. 

Dr. Markus Thomma, CMO of the AutoForm Group, stated: “We are pleased to release AutoForm Assembly R26 with a range of new capabilities and enhancements that further strengthen the BiW assembly process chain. With AutoForm Assembly R26, we are bringing engineering requirements, process simulation, and dimensional accuracy closer together. Our goal is to give engineers the insight they need to identify the causes of dimensional deviations, evaluate alternatives, and address assembly issues before they become costly production problems.”