Research Papers

Variation Simulation of Compliant Metal Plate Assemblies Considering Welding Distortion

[+] Author and Article Information
Wooyoung Choi

Division of Ocean Systems Engineering at Korea
Advanced Institute of Science and Technology,
291 Daehak-ro,
Yuseoung-gu 305-701, South Korea
e-mail: illbethere@kaist.ac.kr

Hyun Chung

Division of Ocean Systems Engineering at Korea
Advanced Institute of Science and Technology,
291 Daehak-ro,
Yuseoung-gu 305-701, South Korea
Ocean Systems Engineering,
KAIST, 291 Daehak-ro,
Daejeon 305-701, South Korea
e-mail: hyunny92@kaist.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received March 11, 2014; final manuscript received February 2, 2015; published online March 2, 2015. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 137(3), 031008 (Jun 01, 2015) (9 pages) Paper No: MANU-14-1101; doi: 10.1115/1.4029755 History: Received March 11, 2014; Revised February 02, 2015; Online March 02, 2015

The shipbuilding industry employs numerous cutting and joining processes to build the ship and offshore structure. Welding, as the primary joining process, inherently causes distortion and accounts for most of the major geometrical variation in the intermediate products (IPs), thus adversarially affecting the downstream assembly processes. Because of the welding process, the variation analysis of compliant assemblies in shipbuilding is clearly different from that of the automobile and aerospace industries, where the distortion during the joining process is negligible. This paper proposes a variation simulation model including the effects of joining process distortion for ships and offshore structures. The proposed model extends the concepts of the sources of variation and the method of influence coefficient (MIC) for a compliant mechanical assembly to include the welding distortions. The proposed model utilizes welding distortion patterns and a transformation matrix to efficiently model the deformation due to the joining process. Also the welding distortions are represented as stochastic values due to its randomness. The model is verified by case study simulation and by a comparison with welding experimental results.

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Fig. 1

Sequence of MIC [24]. (a) Initial variation, (b) clamp part to nominal, (c) weld, and (d) clamp release and assembly spring-back.

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Fig. 2

Metal plate assembly. (a) Boundary condition (BC) and SoV of part variation and (b) BC and SoV of welded structure.

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Fig. 3

Sources of variation for data analysis

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Fig. 4

Simulation result of proposed model using unit deviation. (a) Result of the mean deviation of the assembly and (b) result of the standard deviation of the assembly.

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Fig. 5

Measurement for welding distortion using CMM 3D scanner

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Fig. 6

Designated patterns for validation purpose [33]

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Fig. 7

Analysis of surface data of simulation results. (a) The surface of mean value of simulation results and (b) the surface of standard deviation value of simulation results.

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Fig. 8

Structure and welding sequence of the stack-up process

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Fig. 9

Eigen analysis results of the stack-up process. (a) First eigen-mode, (b) second eigen-mode, (c) third eigen-mode, (d) fourth eigen-mode, (e) fifth eigen-mode, and (f) sixth eigen-mode.




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