In order to achieve the goals of improving product performance index, technological innovation, reducing cost, shortening manufacturing cycle and personalized customization, this article made in-depth technical research on the metal 3D printing Selective Laser Melting (SLM) process to make aluminum alloy (AlSi10Mg) and stainless steel (316L) material parts. The article mainly studied the optimization of metal 3D printing support process, exploration of unsupported technology, mechanical properties of parts and its application in automotive products, and explored its practical application scenarios. According to the exploration results, the article summarized the process guidance specification of metal 3D printing supporting technology and the exploration rules of unsupported technology, and the specific values of mechanical properties of printed parts. Meanwhile, the application scenarios of automobile parts were developed, and the traditional parts with complex, long cycle and high cost were replaced by metal 3D printing laser selective melting (SLM) process. It provides theoretical basis and practical case reference for further application of metal 3D printing technology in automobile parts.

For the differences between BIW aluminum parts joining technology routes in Germany and Japan, the article adopted the research method of typical and benchmarking analysis to describe the principle, forming process and process characteristics of aluminum parts joining technologies of VW AG and Toyota Company, and compared the process technology routes of VW and Toyota from 4 aspects of lightweight, quality, efficiency and cost, and formed a comparative analysis table for the types of BIW aluminum parts and joining processes of VW and Toyota. It is concluded in this article that the types of BIW aluminum parts, joining processes and investment of VW are more than those of Toyota’s, which all meet their quality requirements. The article proposed that FAW should draw on the application experience of aluminum joining technologies of VW and Toyota.

The self piercing riveting & bonding composite connection point with aluminum plate was taken as the research object. In the early stage, through the dynamic tensile test and CAE simulation modeling calibration of the connection point under 3 working conditions of tension shear, tear and forward tension, the parameters in the constitutive relationship of CAE simulation model were accurately obtained. Finally, the comparative verification test of CAE collision simulation and high-speed impact was carried out for T-shaped components with multiple working conditions, CAE simulation accurately predicted and realized the failure of the connection point, and the simulation accuracy reached 95.9%. It accurately characterized the deformation and failure behavior of the riveted-bonded composite connection point under mixed complex working conditions, which has high practicability in the CAE simulation of vehicle collision.

In order to improve the efficiency of the electric drive system for electric vehicles, this article summarized the solutions to improve the efficiency of the electric drive system in motor design, material selection, process assembly and other aspects. In the motor design, motor suitable for the electric vehicle was selected, and the control algorithm was optimized; in terms of materials, copper wires, silicon steel materials and high-frequency materials with high performance were selected; in process assembly, the application of flat wire winding process can improve the torque and efficiency of the motor, the core and stacking process were optimized to reduce the motor iron loss. The efficiency of motor drive system for electric vehicles can be improved by increasing the system output efficiency and reducing various losses.

By studying the principle of resistance spot welding and the actual state of field production, combined with the BOSCH controller, curve analysis of UIR and the splash statistics function, this article analyzed the causes of splash in resistance spot welding. According to the cause of splash, hardware adjustment, parameter adjustment and Bosch software function were adopted to reduce splash rate. The results show that the above experiment effectively reduces splash rate, guarantees welding quality, extends the service life of fixtures, grips and welding clamps and other equipment, and improves the field operation environment of welding.

At present, the disposal of waste solvent for water-borne paint cleaning is a problem of the automotive industry that is difficult to overcome for high disposal cost and high technological difficulty. In order to solve this problem, membrane separation material & recycling technology was invented, which separated and recycled the waste solvent produced in painting and color change and cleaning of painting equipment by membrane separation & recycling technology. In this process, 75% of water was recycled and reused in the painting line, while the paint was extracted to make renewable paint, the material was thus recycled and reused. The technology has been applied to Audi painting line for 2 years with reliable performance, the cost reduction of the 150,000 units painting line exceeded 5 million yuan.

The data of wireless Andon system in the prototyping workshop can indirectly reflect the actual running state of the workshop. In this paper, Qlik Sense was used to establish the analysis model for the data of the current and historical operation states of the Andon system. The current operation state analysis mainly facilitates users to quickly obtain the operation state of the project according to the dimensions of floor/project/workshop; the analysis of historical operation status focuses on the analysis of such dimensions as bottleneck station, single vehicle manufacturing cycle and vehicle delivery in the workshop. Finally, it realized the analysis of data standardization and visualization, helped engineers and managers quickly master workshop operation information, and became an effective tool to assist business improvement.

Based on the Dongfeng vehicle project, the conformal cooling channel consistent of the circuit board shell was established. The effect of the conformal cooling scheme was analyzed by MoldFlow and ANSYS, and compared with the traditional cooling scheme. Finally, the metal 3D printing process was used to fabricate the mold kernel and the cooling channel, which was verified on the injection mold. The results show that the conformal cooling scheme greatly improves the injection efficiency and reduces the deformation of the product.

Due to the effect of internal stress, cold stamped fender has springback deformation, resulting in dimensional deviation. In order to optimize the size of finished parts, CAE simulation tool is used to compensate the springback of parts in the early stamping process design. Taking the steel fender as an example, this paper elaborates a springback compensation method based on the analysis results of CAE simulation, which corrects the position that the size does not meet the standards on the basis of perfecting the simulation file, setting the scale, optimizing the process method, and positioning the parts of the fender. This method is verified by actual production inspection that the dimensional accuracy of the parts is effectively improved.

For the problems of long data preparation time of project engineers in the wireless torque system, this paper first disassembles the data preparation work and clarifies that the issues to be solved are 3 points with long man-hour investment from the “project standards bill of materials” to “tool correctly invoke the tightening program” and standardize the data, and at the same time combine Python, VBA and other programming tools and methods to automate this part of the work. After the actual operation of several projects, the results show that the efficiency of data preprocessing has been improved by 76%, and the use of digital methods has promoted the trial production tightening system to play a further role in promoting intelligence.