Variation Propagation Analysis on Compliant Assemblies Considering Contact Interaction

[+] Author and Article Information
Kang Xie, Lee Wells, Jaime A. Camelio, Byeng D. Youn

Department of Mechanical Engineering–Engineering Mechanics, Michigan Technological University, Houghton, MI 49931

J. Manuf. Sci. Eng 129(5), 934-942 (May 17, 2007) (9 pages) doi:10.1115/1.2752829 History: Received August 03, 2006; Revised May 17, 2007

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.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Predictive contact assembly and method of influence coefficients

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Figure 3

Hood bracket assembly model

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Figure 4

Finite element results from before and after assembly

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Figure 5

Finite element results after assembly, noncontact, and contact linear models: (a) noncontact model; and (b) contact linear model

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Figure 6

Angle response with respect to variables ×3 and ×4: (a) noncontact model; and (b) contact model

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Figure 7

The eDR method with predictive contact model

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Figure 8

Nonlinearity prediction using stepwise moving least squares method

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Figure 9

MCS histogram and eDR method PDF



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