0
TECHNICAL PAPERS

Dimensional Variation Analysis and Synthesis for Composite Components and Assemblies

[+] Author and Article Information
Chensong Dong, Zhiyong Liang, Ben Wang

Department of Industrial Engineering, College of Engineering,  Florida A&M University—Florida State University, Tallahassee, FL 32310

Chuck Zhang1

Department of Industrial Engineering, College of Engineering,  Florida A&M University—Florida State University, Tallahassee, FL 32310

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 127(3), 635-646 (Oct 24, 2004) (12 pages) doi:10.1115/1.1954788 History: Received January 18, 2004; Revised October 24, 2004

This paper presents a study on dimensional variations and tolerance analysis and synthesis for polymer matrix fiber-reinforced composite components and assemblies. A composite component dimensional variation model was developed with process simulation based on thermal stress analysis and finite element analysis (FEA). Using the FEA-based dimensional variation model, the deformations of typical composite structures were studied and the regression-based dimensional variation models were developed. The regression-based dimensional variation models can significantly reduce computation time and provide a quick design guide for composite products with reduced dimensional variations. By introducing a material modification coefficient, the comprehensive regression models can handle various fiber and resin types and stacking sequences, which eliminates the complicated, time-consuming finite element meshing and material parameter defining process. A structural tree method (STM) was developed for rapid computation of composite assembly dimensional variations resulting from deformations on individual components, as well as the deformation of composite components with complex shapes. With the STM and the regression-based dimensional variation models, rapid design optimization was conducted to reduce the dimensional variations of composite assemblies. Cost-tolerance functions were developed using a fuzzy multiattribute utility theory based cost-estimation method. Based on the developed dimensional variation and cost-tolerance models, composite assembly tolerance analysis and synthesis were performed in this study. The exploring research work presented in this paper provides a foundation for developing practical and proactive dimensional control techniques for composite products.

Copyright © 2005 by American Society of Mechanical Engineers
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Figure 1

Research methodology

Grahic Jump Location
Figure 2

Dimensional variation model development and validation

Grahic Jump Location
Figure 3

Spring-in of an L-shaped structure

Grahic Jump Location
Figure 4

Comparison between computational results and experimental results for the L-shaped carbon and epoxy parts

Grahic Jump Location
Figure 5

Spring-in of a single-stiffener structure

Grahic Jump Location
Figure 6

Resin-rich zones

Grahic Jump Location
Figure 7

Typical structures

Grahic Jump Location
Figure 8

Structure with an open window; (a) mesh, (b) deformation

Grahic Jump Location
Figure 9

FEA result for the structure with an open window

Grahic Jump Location
Figure 10

Influences of part size and stiffener thickness on the deformation of structures with an open window

Grahic Jump Location
Figure 11

Influences of part thickness and stiffener thickness on the deformation of structures with an open window

Grahic Jump Location
Figure 12

Influence of fiber volume fraction on the deformation of structures with an open window

Grahic Jump Location
Figure 13

Comparison between fitted and original displacement values of structures with an open window

Grahic Jump Location
Figure 14

Deformation computed from the FEA-based dimensional variation model

Grahic Jump Location
Figure 15

3D assembly of L-shaped structures

Grahic Jump Location
Figure 16

Structural tree for the 3D assembly of L-shaped structures

Grahic Jump Location
Figure 17

Assembly of two single-stiffener structures and one angled structure

Grahic Jump Location
Figure 18

Structural tree for the assembly of two single-stiffener structures and one angled structure

Grahic Jump Location
Figure 19

Cost versus tolerance

Grahic Jump Location
Figure 20

FMAUT-based cost estimation

Grahic Jump Location
Figure 21

Cost-tolerance functions for angular changes

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In