Assembly deviation analysis for large closed thin-walled structures with geometrical deviation and jointed deformation

Abstract

The combined effect of geometrical deviations and jointed deformation in the assembly process are essential for the assembly accuracy of large closed thin-walled cylindrical structures, such as roundness and flatness of the edge, which determines the further assembly between two cylindrical structures. In this paper, a new geometrical deviation propagation model is proposed for large closed cylindrical structures with high local stiffness, in which the geometrical deviation, jointed deformation, and coordinated deformation in the closed assembly process are considered simultaneously. The constraint conditions of the dimensional deviations and shape deviations are derived by small displacement torsor. A virtual deviation feature is developed to describe the equivalent deviation caused by jointed deformation of two cylindrical parts. The correlation of the structural stiffness between unenclosed structure and closed cylindrical structure are established and the geometrical accuracy is obtained by the deformation coordinated conditions. The quantitative index of deviation contribution between parts and assembly is developed based on the deviation propagation model. The influence of geometrical deviation and jointed deformation on the geometric accuracy of assembled structure is revealed. The new deviation propagation model is verified by the experimental data, which may be used for prediction and control of assembly deviation for large closed thin-walled cylindrical structures with high local stiffness.

Keywords

Deviation propagation geometrical deviation jointed deformation virtual deviation feature large closed structure

Get full access to this article

View all access options for this article.

References

Marziale

Polini

A review of two models for tolerance analysis of an assembly: Jacobian and torsor. Int J Comput Integr Manuf 2011; 24(1): 74–86.

Zhu

Anwer

Mathieu

Statistical modal analysis for out-of-plane deviation prediction in additive manufacturing based on finite element simulation. J Manuf Sci Eng 2019; 141(11): 1–35.

Corrado

Polini

Variation analysis of compliant parts in composite material joined by adhesive: A numerical tool. J Manuf Sci Eng 2018; 140(9): 094502.

Zhang

Wang

, et al. Quantitative modeling and decoupling method for assembly deformation analysis considering residual stress from manufacturing process. J Aerosp Eng 2014; 10: 1–18.

Chang

Wang

Jiang

, et al. Modeling and predicting of aeronautical thin-walled sheet metal parts riveting deformation. Assem Autom 2016; 36(3): 295–307.

Liu

Jin

, et al. Compliant assembly analysis including initial deviations and geometric nonlinearity, part II: plate structure. Proc IMechE, Part C: J Mechanical Engineering Science 2019; 233(11): 3717–3732.

Zhao

, et al. Modeling deviation propagation of compliant assembly considering form defects based on basic deviation fields. Assem Autom 2019; 39(1): 226–242.

Pan

Tang

Xing

The deformation analysis, prediction, and experiment verification for thin-wall part assembly based on the fractal theory model with WNNM. Int J Adv Manuf Techol 2017; 92(9–12): 4145–4159.

Arroyave-Tobon

Teissandier

Delos

Tolerance analysis with polytopes in HV-description. J Comput Inf Sci Eng 2016; 17(4): 041011.

10.

Yuan

Wang

, et al. Novel application of mapping method from small displacement torsor to tolerance: error optimization design of assembly parts. Proc IMechE, Part B: J Engineering Manufacture 2022; 236(6–7): 955–967.

11.

Sun

Zhao

Liu

, et al. Assembling deviation estimation based on the real mating status of assembly. Comput Aided Des 2019; 115(10): 244–255.

12.

Desrochers

Rivière

A matrix approach to the representation of tolerance zones and clearances. Int J Adv Manuf Technol 1997; 13(9): 630–636.

13.

Liu

Zhou

Qiu

, et al. Assembly variation analysis of complicated products based on rigid–flexible hybrid vector loop. Proc IMechE, Part B: J Engineering Manufacture 2019; 233(10): 2099–2114.

14.

Desrochers

Ghie

Laperriere

Application of a unified Jacobian-torsor model for tolerance analysis. J Comput Inf Sci Eng 2003; 3(1): 2–14.

15.

Anwer

Ballu

Mathieu

The skin model, a comprehensive geometric model for engineering design. CIRP Ann 2013; 62(1): 143–146.

16.

Peng

Study of 3D tolerance modeling method for complex feature geometric variations. Appl Mech Mater 2016; 851: 567–573.

17.

Zhou

Liu

Qiu

, et al. Three-dimensional tolerance analysis of discrete surface structures based on the torsor cluster model. Assemb Autom 2021; 41(4): 486–500.

18.

Yang

Gao

, et al. Tolerance analysis method considering multifactor coupling based on the Jacobian-torsor model. Adv Mech Eng 2022; 14(12): 1–13.

19.

Zeng

Rao

Modeling of assembly deviation with considering the actual working conditions. Int J Precis Eng Manuf 2019; 20: 791–803.

20.

, et al. Two improved assembly deviation analysis methods based on Jacobian–Torsor matrix and skin model shapes with contact deformation effort. Proc IMechE, Part B: J Engineering Manufacture 2024; 238(6–7): 904–916.

21.

Liu

Zhang

Ding

, et al. Integrating form errors and local surface deformations into tolerance analysis based on skin model shapes and a boundary element method. Comput Aided Des 2018; 104: 45–59.

22.

Liu

, et al. A generic integrated approach of assembly tolerance analysis based on skin model shapes. Proc IMechE, Part B: J Engineering Manufacture 2021; 235(4): 689–704.

23.

Sun

Tian

, et al. Assembly deviation analysis of satellite flexible parts integrating rigid and flexible properties: modeling and experiment. Proc IMechE, Part B: J Engineering Manufacture. Epub ahead of print 16 April 2024. DOI: 10.1177/09544054241245017.

24.

Xiong

Precision assembly simulation of skin model shapes accounting for contact deformation and geometric deviations for statistical tolerance analysis method. Int J Precis Eng Manuf 2021; 22(6): 975–989.

25.

Gao

, et al. Modeling and analysis of assembly variation with non-uniform stiffness condensation for large thin-walled structures. Thin Wall Struct 2023; 191: 111042.

26.

, et al. Out-of-plane distortion prediction of large thin-walled structures induced by friction stir welding. Sci Technol Weld Joining 2020; 25(1): 45–55.