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Research Papers

Variation Propagation Analysis for Multistation Assembly Process With Consideration of GD&T Factors

[+] Author and Article Information
Zhenyu Kong1

School of Industrial Engineering and Management, Oklahoma State University, Stillwater, OK 74078

Wenzhen Huang

Department of Mechanical Engineering, University of Massachusetts, Dartmouth, MA 02747

Asil Oztekin

School of Industrial Engineering and Management, Oklahoma State University, Stillwater, OK 74078

1

Corresponding author.

J. Manuf. Sci. Eng 131(5), 051010 (Sep 23, 2009) (10 pages) doi:10.1115/1.4000094 History: Received April 04, 2008; Revised July 23, 2009; Published September 23, 2009

Modeling of variation propagation in multistation assembly processes is crucial in predicting product dimensional quality and general performance of manufacturing systems. Based on the state space modeling, this paper develops a variation propagation model, which can be applied for analysis of various tolerances such as size tolerance, bonus tolerance, floating tolerance, etc. The nonstationary tolerance/variation (varying variance) caused by bonus tolerance and floating tolerance is properly handled by the proposed method. Thus, by using the developed variation propagation model, the variations on key product characteristics (KPCs) can be accurately predicted. This enables broad applications of the proposed method in actual manufacturing processes. The results of the case study also validated the proposed model.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

Diagram of a multistation assembly process

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Figure 2

A schematic diagram of 3–2-1 fixture layout (6)

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Figure 3

Schematic of 4-way pin/hole and 2-way pin/slot

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Figure 4

Example of size tolerance of a hole

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Figure 5

Combination of size tolerance and position tolerance

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Figure 6

Actual size of the combination of the two tolerances in Fig. 5

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Figure 7

GD&T representation of bonus tolerance

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Figure 8

Illustration of circular tolerance

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Figure 9

Simulation results of toleranced points with circular position tolerance

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Figure 10

Illustration of the assembly process

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Figure 11

Diagram of the final assembled part

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Figure 12

Comparison of the results between 3DCS simulation and the proposed method

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