Compliant assembly variation analysis of sheet metal with shape errors based on primitive deformation patterns. (July 2018)

• Record Type: Journal Article
• Authors: Li, Yunyong; Zhao, Yong; Yu, Haidong; Lai, Xinmin
• Is Part Of: Proceedings of the Institution of Mechanical Engineers. Volume 232:Number 13(2018)
• Page Start: 2334
• Page End: 2351
• Publication Date: 2018-07
• Subjects: Compliant assembly -- variation propagation -- shapes errors -- primitive deformation patterns -- pattern coefficients -- dimension error field; Mechanical engineering -- Periodicals; 621.05
• DOI: 10.1177/0954406217720231
• Languages: English
• ISSNs: 0954-4062

Abstract

In the compliant assembly of sheet metal, the performance of the product is highly related to the shape errors of surface. Therefore, variation analysis is generally required to reveal the influence principle of the components' manufacturing variations on the surface shape errors of the product. The traditional compliant assembly variation analysis methods were used to build a variation propagation model based on characteristic points between parts and product without considering shape errors. In this paper, a new method based on primitive deformation patterns considering shape errors is proposed. The primitive deformation patterns of part can be obtained by natural mode analysis of ideal part, and the primitive deformation patterns of product can be calculated by the dynamic substructure method. The initial shape errors of part are decomposed into the individual contributions of primitive deformation patterns. Considering the force equilibrium relationship in assembly process, a variation propagation model is built based on the primitive deformation patterns between parts and product. This model reveals variation propagation in assembly process by the basic element of dimension error field (deformation patterns), which is convenient for evaluating the assembly quality. A case study on a panel parts assembly process is presented to demonstrate the proposed variation analysis method. The results show the effectiveness and accuracy of the proposed method compared with the method of finite element analysis conducted in commercial software ABAQUS.