Shimming position and amount have a significant influence on the weight and mechanical performance of the thin-walled product that having assembly gap during aerospace components assembly process. An analytical method for assembly-induced deformation prediction of the bolted composite joints with assembly gap was developed. The assembly-induced deformation under the preloading force was computed as bending deformation and bolt head compression deformation by evaluating whether assembly gap can be eliminated and whether the calculating point is within the conical and spherical envelope of the fastener. The proposed method was validated by the preloading experiment of three-bolt composite joints with relative error less than 10%. Then it was applied to analyse the assembly-induced deformation of a composite box structure including composite spars and skins. Under the guide of the analytical result, shimming assembly of the composite box structure was carried out. The proposed analytical method has a good application prospect to predict the assembly-induced deformation during preloading process for composite/composite joints or composite/metal joints.
Vojnić-PurčarMProkićABeševićM. A numerical model for laminated composite thin-walled members with openings considering shear lag effect. Eng Struct2019; 185: 392–399.
2.
GalosJ. Thin-ply composite laminates: a review. Compos Struct2020; 236: 111920.
CamanhoPTongL. Composite joints and connections. Oxford: Woodhead Publishing Limited, 2011.
5.
RenX-qChenCRanX-k, et al. Microstructure evolution of AA5052 joint failure process and mechanical performance after reconditioning with tubular rivet. T Nonferr Metal Soc2021; 31: 3380–3393.
6.
ChenCWuJLiH. Optimization design of cylindrical rivet in flat bottom riveting. Thin Wall Struct2021; 168: 108292.
7.
ZhangXChenC. Experimental investigation of joining aluminum alloy sheets by stepped mechanical clinching. J Mater Res Technol2022; 19: 566–577.
8.
ShiCLiHChenC, et al. Experimental investigation of the flat clinch–rivet process. Thin Wall Struct2022; 171: 108612.
9.
SaadatMCretinC. Dimensional variations during Airbus wing assembly. Assembly Autom2002; 22: 270–276.
10.
YuanZWangYPengX, et al. An analytical model on through-thickness stresses and warpage of composite laminates due to tool–part interaction. Compos Part B2016; 91: 408–413.
11.
BaranICinarKErsoyN, et al. A review on the mechanical modeling of composite manufacturing processes. Arch Comput Method Eng2017; 24: 365–395.
12.
CoxAHerbertSVillain-ChastreJP, et al. The effect of machining and induced surface deformation on the fatigue performance of a high strength metastable β titanium alloy. Int J Fatigue2019; 124: 26–33.
13.
Al-DhaheriMKhanKAUmerR, et al. Process-induced deformation in U-shaped honeycomb aerospace composite structures. Compos Struct2020; 248: 112503.
14.
WangZZhangS-WWangN, et al. A feature-based assembly information modeling method for complex products’ 3D assembly design. Proc IMechE, Part B: J Engineering Manufacture2023; 237(9): 1311–1325.
15.
QingWDouYLiJ, et al. An assembly gap control method based on posture alignment of wing panels in aircraft assembly. Assembly Autom2017; 37: 422–433.
16.
LiHQiuLWangZ, et al. An assembly precision prediction method for customized mechanical products based on GAN-FTL. Proc IMechE, Part B: J Engineering Manufacture2021; 236: 160–173.
17.
GoeringJBohlmannRWanthalS, et al. Assembly induced delaminations in composite structures. In: SoderquistJRNeriLMBohonHL (eds). Ninth DOD (NASA) FAA conference on fibrous composites in structural design, NV, US, 1992, pp. 1353–1377. New Jersey: FAA Technical Center.
18.
CampbellFC. Manufacturing processes for advanced composites. Oxford: Elsevier Science, 2003.
19.
ChouvionBPopovARatchevS, et al. Interface management in wing-box assembly. SAE technical paper 2011-01-2640, 2011.
20.
LiuXChangJYangY, et al. Evaluation of assembly gap from 3D laser measurements via FEA simulation. Int J Aerospace Eng2018; 2018: 4303105.
21.
CrossleyRRatchevS. Aerospace assembly gap measurement using low cost smart tools with machine vision. In: RatchevS (ed.) Precision assembly in the digital age. Cham, Switzerland: Springer International Publishing, 2019, pp.158–168.
22.
LacroixCMathieuLThiébautF, et al. Numerical process based on measuring data for gap prediction of an assembly. Procedia CIRP2015; 27: 97–102.
23.
LiSHaoLHuangX, et al. A shimming method based on outer mold line control of thin-walled parts. Proc IMechE, Part B: J Engineering Manufacture2022; 237: 715–730.
24.
ZhaiYLiDLiX, et al. An experimental study on the effect of joining interface condition on bearing response of single-lap, countersunk composite-aluminum bolted joints. Compos Struct2015; 134: 190–198.
25.
LiuLZhangJChenK, et al. Experimental and numerical analysis of the mechanical behavior of composite-to-titanium bolted joints with liquid shim. Aerosp Sci Technol2016; 49: 167–172.
26.
ManoharKHoganTButtrickJ, et al. Predicting shim gaps in aircraft assembly with machine learning and sparse sensing. J Manuf Syst2018; 48: 87–95.
27.
YangYWangY-QLiuX, et al. The effect of shimming material on flexural behavior for composite joints with assembly gap. Compos Struct2019; 209: 375–382.
28.
YangYLiuXWangY-Q, et al. An enhanced spring-mass model for stiffness prediction in single-lap composite joints with considering assembly gap and gap shimming. Compos Struct2018; 187: 18–26.
29.
YangYBaoYWangJ, et al. Extended spring–mass method for joint stiffness prediction of single-lap multi-bolt composite joints considering assembly gap and gap shimming. Mech Adv Mater Struc2022; 29: 5911–5922.
30.
YueXAnLYeX, et al. Effect of gap and shims on the strain and stress state of the composite-aluminum hybrid bolted structure. Int J Aerospace Eng2020; 2020: 8811484.
31.
YangY. Research on bolted joint performance of CFRP components considering shimming assembly (in Chinese). PhD Thesis, Dalian University of Technology, China, 2019.
32.
NassarSAAbboudA. An improved stiffness model for bolted joints. J Mech Des2009; 131: 121001–121011.
33.
GrayPJMcCarthyCT. An analytical model for the prediction of through-thickness stiffness in tension-loaded composite bolted joints. Compos Struct2012; 94: 2450–2459.
34.
NelsonWDBuninBLHart-SmithLJ. Critical joints in large composite aircraft structure. Report no. NASA Contractor Report 3710, 1983. DTIC Document. California: Douglas Aircraft Company.
35.
MandalBChakrabartiA. A simple homogenization scheme for 3D finite element analysis of composite bolted joints. Compos Struct2015; 120: 1–9.
MengMLeHRRizviMJ, et al. The effects of unequal compressive/tensile moduli of composites. Compos Struct2015; 126: 207–215.
38.
YangYLiuXWangY-Q, et al. A progressive damage model for predicting damage evolution of laminated composites subjected to three-point bending. Compos Sci Technol2017; 151: 85–93.
