A new assembly variation analysis model based on the method of power balance for auto-body parts

2014 ◽  
Vol 34 (3) ◽  
pp. 296-302 ◽  
Author(s):  
Yanfeng Xing ◽  
Yansong Wang
Keyword(s):  
Sheet Metal ◽  
Power Balance ◽  
Influence Coefficient ◽  
Body Parts ◽  
Variation Analysis ◽  
Analysis Model ◽  
Content Type ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Auto Body

Purpose – The purpose of this paper is to propose a new assembly variation analysis model to analyze assembly variation for sheet metal parts. The main focus is to analyze assembly processes based on the method of power balance. Design/methodology/approach – Starting with issues in assembly variation analysis, the review shows the critical aspects of tolerance analysis. The method of influence coefficient (MIC) cannot accurately analyze the relationship between part variations and assembly variations, as the welding point is not a point but a small area. Therefore, new sensitivity matrices are generated based on the method of power balance. Findings – Here two cases illustrate the processes of assembly variation analysis, and the results indicate that new method has higher accuracy than the MIC. Research limitations/implications – This study is limited to assembly variation analysis for sheet metal parts, which can be used in auto-body and airplane body. Originality/value – This paper provides a new assembly variation analysis based on the method of power balance.

Assembling Variation Analysis Based on Power Balance Method for Sheet Metal Parts

2013 ◽  
Vol 303-306 ◽  
pp. 2585-2588 ◽  
Author(s):  
Yan Feng Xing ◽  
Xin Lu ◽  
Yan Song Wang
Keyword(s):  
Sheet Metal ◽  
Welding Process ◽  
Power Balance ◽  
Influence Coefficient ◽  
Variation Analysis ◽  
Analysis Model ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Analysis Process ◽  
The Relationship

Sheet metal parts are widely used in auto body and airplane body. As the method of influence coefficient cannot accurately analyze the relationship between part deviations and assembly variations, this paper proposes a new variation analysis model based on a method of power balance for sheet metal parts. The simple metal planes are loaded to fixtures according to the principle of “4-2-1”; and then variety of part deviations is analyzed during assembly process. The analysis shows that the welding guns do same work during welding process. Based on the above, this work establishes sensitive coefficient matrices between part deviations and assembly variations. Finally, two Z-shape sheet metal parts illustrate the assembling variation analysis process and the results indicate the accuracy of the method of power balance.

Minimizing assembly variation in selective assembly for auto-body parts based on IGAOT

2018 ◽  
Vol 11 (2) ◽  
pp. 254-268 ◽  
Author(s):  
Yanfeng Xing ◽  
Yansong Wang
Keyword(s):  
Genetic Algorithm ◽  
Sheet Metal ◽  
Rigid Bodies ◽  
Influence Coefficient ◽  
Body Parts ◽  
Selective Assembly ◽  
Improved Genetic Algorithm ◽  
Content Type ◽  
Sheet Metal Parts ◽  
Assembly Tolerance

PurposeDimensional quality of sheet metal assemblies is an important factor for the final product. However, the part tolerance is not easily controlled because of the spring back deformation during the stamping process. Selective assembly is a means to decrease assembly tolerance of the assembly from low-precision components. Therefore, the purpose of this paper is to propose a fully efficient method of selective assembly optimization based on an improved genetic algorithm for optimization toolbox (IGAOT) in MATLAB.Design/methodology/approachThe method of influence coefficient is first applied to calculate the assembly variation of sheet metal components since the traditional rigid assembly variation model cannot be used due to welding deformation. Afterwards, the IGAOT is proposed to generate optimal selective groups, which consists of advantages of genetic algorithm for optimization toolbox (GAOT) and simulated annealing.FindingsThe cases of two simple planes and the tail lamp bracket assembly are used to illustrate the flowchart of optimizing combinations of selective groups. These cases prove that the proposed IGAOT has better precision than that of GAOT with the same parameters for selective assembly.Originality/valueThe research objective of this paper is to evaluate the changes from rigid bodies to sheet metal parts which are very complex for selective assembly. The method of IGAOT was proposed to the selected groups which has better precision than that of current optimization algorithms.

Variation Analysis of Sheet Metal Assemblies with Fixture Configuration

2012 ◽  
Vol 170-173 ◽  
pp. 3283-3287
Author(s):  
Yan Feng Xing ◽  
Yan Song Wang ◽  
Xiao Yu Zhao
Keyword(s):  
Sheet Metal ◽  
Influence Coefficient ◽  
Variation Analysis ◽  
Wind Noise ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Linear Relationships ◽  
Deviation Propagation ◽  
Fixture Configuration ◽  
Assembly Variation Modeling

The dimensional quality of auto-body relates to the whole external appearance and wind noise, the effect of closing the door and even driving smoothness of vehicles. The deviation propagation can be analyzed through the method of influence coefficient (MIC). However, fixture deviation usually impacts on the assembly variation than part variation. A variation analysis modeling with fixture configuration is presented to improve the current variation analysis efficiency of sheet metal parts. The variation change process of part, fixture and assembly was analyzed by researching the locating and assembly process of sheet metal parts. The linear relationships among variations of parts, fixtures and assemblies are established with two locating principles of “N-2-1” and “3-2-1”. Moreover, in accordance with the different release modes of the fixture locating points after the assembly, the assembly variation modeling is established in the two modes of over-constrained release and full release. Finally, a case of sheet metal assembly is illustrated to show the effectiveness of the assembly variation analysis modeling.

Analysis of Nonlinear Variation Accumulation in Auto-Body Assembly Process

Manufacturing ◽  
2002 ◽  
Author(s):  
Jun Lian ◽  
Zhongqin Lin ◽  
Fusheng Yao ◽  
Xinmin Lai
Keyword(s):  
Sheet Metal ◽  
State Equation ◽  
Assembly Process ◽  
Transformation Mechanism ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Accumulation Mechanism ◽  
Auto Body ◽  
Non Gaussian ◽  
Geometrical Dimensions

In the assembly process of auto-body, variations in the geometrical dimensions of sheet metal parts and fixtures are inevitable. These variations accumulate through the multi-station assembly process to form the dimensional variations of the final products. Compared with the assembly of rigid parts, the assembly process of the elastic parts is more complex because the variation accumulation patterns rely much on the variations of fixture, jointing methods and mechanical deformation. This paper aims at analyzing the variation transformation mechanism and accumulation characteristics for the assembly of sheet metal parts based on the analysis of dimensional coordination relations among parts and fixtures. Finite element method (FEM) and Monte-Carlo Simulation (MCS) were used to analyze the effect of jointing contact on variation transformation, while a state equation was developed to describe the variation accumulation mechanism. The result of the analysis indicates that the main characteristics of elastic assembly jointing are the overlap jointing methods and elastic contacts action. The fact that the variation transform coefficients (VTC) are variable makes the assembly variation distribution Non-Gaussian even if the dimension variation of parts is Gaussian distribution. The analysis conclusions have potential value for more reasonable tolerance synthesis of elastic parts assembly.

scholarly journals Automated Point-based Tolerance Analysis Model Creation for Sheet Metal Parts

Procedia CIRP ◽  
2015 ◽  
Vol 27 ◽  
pp. 65-70 ◽  
Author(s):  
F. Litwa ◽  
M. Gottwald ◽  
M. Bohn ◽  
J.F. Klinger ◽  
M. Walter ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Tolerance Analysis ◽  
Analysis Model ◽  
Metal Parts ◽  
Sheet Metal Parts

Modeling and predicting of aeronautical thin-walled sheet metal parts riveting deformation

2016 ◽  
Vol 36 (3) ◽  
pp. 295-307 ◽  
Author(s):  
Zhengping Chang ◽  
Zhongqi Wang ◽  
Bo Jiang ◽  
Jinming Zhang ◽  
Feiyan Guo ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Element Model ◽  
Local Deformation ◽  
Calculation Model ◽  
Content Type ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thin Walled ◽  
The Impact ◽  
Successive Calculation

Purpose Riveting deformation is inevitable because of local relatively large material flows and typical compliant parts assembly, which affect the final product dimensional quality and fatigue durability. However, traditional approaches are concentrated on elastic assembly variation simulation and do not consider the impact of local plastic deformation. This paper aims to present a successive calculation model to study the riveting deformation where local deformation is taken into consideration. Design/methodology/approach Based on the material constitutive model and friction coefficient obtained by experiments, an accurate three-dimensional finite element model was built primarily using ABAQUS and was verified by experiments. A successive calculation model of predicting riveting deformation was implemented by the Python and Matlab and was solved by the ABAQUS. Finally, three configuration experiments were conducted to evaluate the effectiveness of the model. Findings The model predicting results, obtained from two simple coupons and a wing panel, showed that it was a good compliant with the experimental results, and the riveting sequences had a significant effect on the distribution and magnitude of deformation. Practical implications The proposed model of predicting the deformation from riveting process was available in the early design stages, and some efficient suggestions for controlling deformation could be obtained. Originality/value A new predicting model of thin-walled sheet metal parts riveting deformation was presented to help the engineers to predict and control the assembly deformation more exactly.

Experimental and Numerical Analysis of Blanking for Thin Sheet Metal Parts

2001 ◽  
Vol 4 (3-4) ◽  
pp. 319-333
Author(s):  
Vincent Lemiale ◽  
Philippe Picart ◽  
Sébastien Meunier
Keyword(s):  
Numerical Analysis ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thin Sheet Metal
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