Variation Propagation Analysis on Compliant Assemblies Considering Contact Interaction

2007 ◽  
Vol 129 (5) ◽  
pp. 934-942 ◽  
Author(s):  
Kang Xie ◽  
Lee Wells ◽  
Jaime A. Camelio ◽  
Byeng D. Youn
Keyword(s):  
Contact Interaction ◽  
Thermal Deformation ◽  
Linear Process ◽  
Assembly Process ◽  
Physical Processes ◽  
Propagation Analysis ◽  
Variation Propagation ◽  
Highly Nonlinear ◽  
Dimensional Variation

Dimensional variation is inherent to any manufacturing process. In order to minimize its impact on assembly products it is important to understand how the variation propagates through the assembly process. Unfortunately, manufacturing processes are complex and in many cases highly nonlinear. Traditionally, assembly process modeling has been approached as a linear process. However, many assemblies undergo highly complex nonlinear physical processes, such as compliant deformation, contact interaction, and welding thermal deformation. This paper presents a new variation propagation methodology considering the compliant contact effect, which will be analyzed through nonlinear frictional contact analysis. Its variation prediction will be accurately and efficiently conducted using an enhanced dimension reduction method. A case study is presented to show the applicability of the proposed methodology.

Variation Propagation Analysis on Compliant Assemblies Considering Contact Interaction

2006 ◽  
Author(s):  
Kang Xie ◽  
Lee Wells ◽  
Jaime A. Camelio ◽  
Byeng D. Youn
Keyword(s):  
Linear Response ◽  
Reduction Method ◽  
Linear Process ◽  
Manufacturing Processes ◽  
Assembly Process ◽  
Dimension Reduction Method ◽  
Propagation Analysis ◽  
Variation Propagation ◽  
Non Linear ◽  
Dimensional Variation

Dimensional variation is inherent to any manufacturing process. In order to minimize its impact on assembly products is important to understand how it propagates through the assembly process. Unfortunately, manufacturing processes are complex and in many cases highly non-linear. Traditional assembly models have represented assembly as a linear process. However, assemblies that include the contact between their components and tools show a highly non-linear response. This paper presents a new assembly methodology considering the contact effect. In addition, an efficient to predict output response is presented. The enhance dimension reduction method (eDR) is used to accurately and efficiently predict the statistical response of the assembly to variation on the input parameters.

scholarly journals Assembly Variation Analysis of Aircraft Panels under Part-to-part Locating Scheme

2019 ◽  
Vol 2019 ◽  
pp. 1-15 ◽  
Author(s):  
Xia Liu ◽  
Luling An ◽  
Zhiguo Wang ◽  
Changbai Tan ◽  
Xiaoping Wang ◽  
...  
Keyword(s):  
Elastic Deformation ◽  
Assembly Process ◽  
Variation Analysis ◽  
Kinematic Theory ◽  
Statistical Variation ◽  
Variation Propagation ◽  
Fixed Part ◽  
Compliant Parts ◽  
Aircraft Panels

A typical aircraft panel is the assembly consisting of a multitude of thin and lightweight compliant parts. In panel assembly process, part-to-part locating scheme has been widely adopted in order to reduce fixtures. By this locating scheme, a part is located onto the pre-fixed part/subassembly by determinant assembly (DA) holes, and temporary fasteners (e.g., spring pin) are used for joining these DA hole-hole pairs. The temporary fasteners can fasten DA hole-hole pairs in the axial and radial directions of DA holes. The fastening in the radial directions is realized by the expansion of temporary fasteners. Although the usage of temporary fasteners helps reduce the positional differences between hole-hole pairs, their clamping forces thereby may lead to elastic deformation of compliant parts/subassemblies. Limited research has been conducted on such elastic deformation produced by temporary fastener and its influence on assembly dimensional quality. This paper proposes a novel rigid-compliant variation analysis method for aircraft panel assembly, incorporating the deformation in part-to-part locating process. Based on the kinematic theory and linear elasticity deformation assumption, the variation propagation through the locating process, as well as the entire assembly process of an aircraft panel, is formulated. Then, the statistical variation analysis is performed with Monte Carlo (MC) simulation. Finally, the proposed method is validated by a case study. The result shows the deformation in the part-to-part locating process significantly impacts the assembly variations, and our method can provide a more accurate and reliable prediction.

Propagation analysis of variation for fuselage structures in multi-station aircraft assembly

2018 ◽  
Vol 38 (1) ◽  
pp. 67-76 ◽  
Author(s):  
Liang Cheng ◽  
Qing Wang ◽  
Jiangxiong Li ◽  
Yinglin Ke
Keyword(s):  
Propagation Model ◽  
Analysis Approach ◽  
Good Prediction ◽  
Assembly Process ◽  
Content Type ◽  
Modeling And Analysis ◽  
Aircraft Assembly ◽  
Propagation Analysis ◽  
Variation Propagation ◽  
Large Aircraft

Purpose This paper aims to present a modeling and analysis approach for multi-station aircraft assembly to predict assembly variation. The variation accumulated in the assembly process will influence the dimensional accuracy and fatigue life of airframes. However, in digital large aircraft assembly, variation propagation analysis and modeling are still unresolved issues. Design/methodology/approach Based on an elastic structure model and variation model of multistage assembly in one station, the propagation of key characteristics, assembly reference and measurement errors are introduced. Moreover, the reposition and posture coordination are considered as major aspects. The reposition of assembly objects in a different assembly station is described using transformation and blocking of coefficient matrix in finite element equation. The posture coordination of the objects is described using homogeneous matrix multiplication. Then, the variation propagation model and analysis of large aircraft assembly are established using a discrete system diagram. Findings This modeling and analysis approach for multi-station aircraft assembly reveals the basic rule of variation propagation between adjacent assembly stations and can be used to predict assembly variation or potential dimension problems at a preliminary assembly phase. Practical implications The modeling and analysis approaches have been used in a transport aircraft project, and the calculated results were shown to be a good prediction of variation in the actual assembly. Originality/value Although certain simplifications and assumptions have been imposed, the proposed method provides a better understanding of the multi-station assembly process and creates an analytical foundation for further work on variation control and tolerance optimization.

Product Tolerance Allocation in Compliant Multistation Assembly Through Variation Propagation and Analytical Target Cascading

2004 ◽  
Author(s):  
Zhijun Li ◽  
Jianpeng Yue ◽  
Michael Kokkolaras ◽  
Jaime Camelio ◽  
Panos Y. Papalambros ◽  
...  
Keyword(s):  
Linear Process ◽  
Tolerance Allocation ◽  
Vehicle Body ◽  
Analytical Target Cascading ◽  
Variation Propagation ◽  
Target Cascading ◽  
Dimensional Variation ◽  
Product Variation ◽  
Multistation Assembly ◽  
Sheet Metal Assembly

Compliant sheet metal assembly is a hierarchical manufacturing process that plays a significant role in automotive product development. Parts are joined in different stations to form the final product (e.g., the vehicle body structure). Dimensional variation is a product attribute of major importance that characterizes quality, and is mainly affected by the variability of parts, fixtures, and joining methods at each of the multiple stations. The propagation of dimensional variation through the multistation assembly system is modeled as a linear process, where all three aforementioned sources of variability are taken into account at each station using finite element models. In this article we apply the analytical target cascading process to the tolerance allocation problem in multistation assembly systems. Specifically, we translate final product variation targets to tolerance specifications for subassemblies and incoming parts. We demonstrate the methodology by means of a vehicle side frame assembly example.

Modeling Variation Propagation Based on State Space and its Application to Dimensional Variation Prediction in Shipbuilding

2011 ◽  
Vol 291-294 ◽  
pp. 2889-2892
Author(s):  
Xiang Rui Liu ◽  
Zhi Ying Zhang
Keyword(s):  
State Space ◽  
Assembly Process ◽  
Accuracy Control ◽  
Dimensional Control ◽  
Shipbuilding Industry ◽  
Locating Error ◽  
Variation Propagation ◽  
Dimensional Variation ◽  
Block Construction ◽  
Stream Model

Dimensional control is one of the most important challenges in shipbuilding industry. In order to predict assembly dimensional variation in block construction of shipbuilding, a variation stream model based on state space is presented in this paper, which can be further applied to accuracy control. Both locating error and welding deformation are taken into consideration in this model, and variation propagation mechanisms and accumulative rule in the assembly process are analyzed, then, a model is developed to describe the variation propagation throughout the assembly process, finally, an example of flat block construction is given to provide this method is effective and useful.

Optimal Design of Fixture Layout for Compliant Part With Application in Ship Curved Panel Assembly

2020 ◽  
Vol 143 (6) ◽  
Author(s):  
Juan Du ◽  
Changhui Liu ◽  
Jianfeng Liu ◽  
Yansong Zhang ◽  
Jianjun Shi
Keyword(s):  
Optimal Design ◽  
Simulated Annealing Algorithm ◽  
Assembly Process ◽  
Fixture Layout ◽  
Compliant Part ◽  
Curved Panel ◽  
Dimensional Variation ◽  
Direct Stiffness ◽  
Compliant Parts

Abstract In a ship assembly process, a large number of compliant parts are involved. The ratio of the part thickness to the length or the width is typically 0.001–0.012. Fixture design is a critical task in the ship assembly process due to its impact on the deformation and dimensional variation of the compliant parts. In current practice, fixtures are typically uniformly distributed under the part to be assembled, which is non-optimal, and large dimensional gaps may occur during assembly. This paper proposed a methodology for the optimal design of the fixture layout in the ship assembly process by systematically integrating direct stiffness method and simulated annealing algorithm, which aims to minimize dimensional gaps along the assembly interface to further improve the quality and efficiency of seam welding. The case study shows that the proposed method significantly reduced the dimensional gaps of the compliant curved panel parts in a ship assembly process.

Modeling Variation Propagation of Multi-Station Assembly Systems With Compliant Parts

2001 ◽  
Author(s):  
Jaime A. Camelio ◽  
S. Jack Hu ◽  
Dariusz J. Ceglarek
Keyword(s):  
Space Representation ◽  
State Space Representation ◽  
Automotive Body ◽  
Compliant Assembly ◽  
Variation Propagation ◽  
Sources Of Variation ◽  
Dimensional Variation ◽  
Compliant Parts ◽  
And Performance

Abstract Products made of compliant sheet metals are widely used in automotive, aerospace, appliance and electronics industries. One of the most important challenges for the assembly process of such compliant parts is the assembly dimensional quality, which affects product functionality and performance. This paper develops a methodology to evaluate the dimensional variation propagation in a multi-station compliant assembly system based on linear mechanics and a state space representation. Three sources of variation are analyzed, part variation, fixture variation and weld gun variation. The proposed method is illustrated through a case study on automotive body assembly.

Modeling Variation Propagation of Multi-Station Assembly Systems With Compliant Parts

2003 ◽  
Vol 125 (4) ◽  
pp. 673-681 ◽  
Author(s):  
Jaime Camelio ◽  
S. Jack Hu ◽  
Dariusz Ceglarek
Keyword(s):  
Space Representation ◽  
Assembly Process ◽  
State Space Representation ◽  
Automotive Body ◽  
Compliant Assembly ◽  
Variation Propagation ◽  
Sources Of Variation ◽  
Dimensional Variation ◽  
Compliant Parts ◽  
And Performance

Products made of compliant sheet metals are widely used in automotive, aerospace, appliance and electronics industries. One of the most important challenges for the assembly process with compliant parts is dimensional quality, which affects product functionality and performance. This paper develops a methodology to evaluate the dimensional variation propagation in a multi-station compliant assembly system based on linear mechanics and a state space representation. Three sources of variation: part variation, fixture variation and welding gun variation are analyzed. The proposed method is illustrated through a case study on an automotive body assembly process.

Integration of in-plane and out-of-plane dimensional variation in multi-station assembly process for automotive body assembly

2019 ◽  
Vol 234 (6) ◽  
pp. 1690-1702
Author(s):  
Vahid Jandaghi Shahi ◽  
Abolfazl Masoumi
Keyword(s):  
Transfer Function ◽  
Sheet Metal ◽  
Assembly Process ◽  
Assembly Operation ◽  
Automotive Body ◽  
Variation Propagation ◽  
Out Of Plane ◽  
Dimensional Variation ◽  
Plane Direction ◽  
Assembly Operations

Automotive body assembly systems contain multiple operations in multi-station processes. One of the most critical challenges for such manufacturing systems is dimensional quality, which is affected by the accumulation and propagation of variation caused by manufacturing imperfections. However, sheet metal part compliancy behavior makes the variation modeling method extremely intricate when both rigid (in-plane) and compliant (out-of-plane) variations are considered. This paper develops a more accurate variation propagation model to describe dimensional variation of sheet metal assembly in multi-station assembly system through involving both the variation types simultaneously as well as the impacts of assembly operations on each other. In this methodology, three sources of deviations—non-ideal parts, fixture errors, and assembly operations effects—are taken into account. The variation generated in every assembly operation (placing, clamping, fastening, and releasing steps) and the variation propagation through station-to-station interaction (repositioning) are analyzed by the transfer function mechanism. In the in-plane direction, the stream of variation analysis is adopted to obtain the rigid transfer function to describe the position and orientation relationships between part and assembly element errors. For the simulation of part deformation during the assembly process in the out-of-plane direction, the compliant transfer functions are extracted by variation response methodology. A nested state space model is used to integrate the overall assembly variation by updating part geometry after each assembly operation. The capability of proposed method is illustrated through a case study on an automotive body side assembly process.

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