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Research Papers

A Local-to-Global Dimensional Error Calculation Framework for the Riveted Assembly Using Finite-Element Analysis

[+] Author and Article Information
Jun Ni

School of Mechanical Engineering,
Jiulong Lake Campus,
Southeast University,
Nanjing 211189, China
e-mail: juuuuny@live.cn

Wencheng Tang

School of Mechanical Engineering,
Jiulong Lake Campus,
Southeast University,
Nanjing 211189, China
e-mail: tangwc@seu.edu.cn

Yan Xing

School of Mechanical Engineering,
Jiulong Lake Campus,
Southeast University,
Nanjing 211189, China
e-mail: xingyan@seu.edu.cn

Kecun Ben

Nanjing Research Institute
of Electric Technology,
Nanjing 210039, China
e-mail: benkecun@163.com

Ming Li

Nanjing Research Institute
of Electric Technology,
Nanjing 210039, China
e-mail: liming607@hotmail.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received November 13, 2014; final manuscript received July 14, 2015; published online October 1, 2015. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 138(3), 031004 (Oct 01, 2015) Paper No: MANU-14-1592; doi: 10.1115/1.4031101 History: Received November 13, 2014; Revised July 14, 2015

Mechanical structures of large-scale antennas are sheet metals connected by thousands of rivets. The antenna dimensional error after riveting often violates the limit allowed. The prediction of the global dimensional error induced by many rivet connections requires a rapid and accurate assembly deformation calculation method. Main process parameters of these local rivet connections are the local connection dimension, material property, local clamp position, rivet upsetting direction, and the hammer time-to-displacement impact, except for the riveting sequence. We neglect the process parameter uncertainties and consider that the main riveting parameters equate to a dynamic finite-element (FE) model of single rivet connection. The dynamic FE analysis result yields an inherent strain database for the riveted local parts. Then, we propose an iterative loop of static FE analyses for the global structure taking the inherent strain database and possible former static FE analysis result as the boundary conditions. The loop forms a local-to-global framework. Two examples are involved through the framework representation and realistic application. Framework advantages include: (1) a good balance between the cost and precision of dimensional error calculation; (2) the sequence simulation of all the riveting operations; and (3) supporting the further assembly process optimization to reduce the global dimensional error of the assembly with thousands of rivets.

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Figures

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Fig. 1

Information for the assembly with four rivets: (a) geometric model, (b) FEs, and (c) boundary conditions

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Fig. 2

Dynamic analysis result of the single rivet connection: (a) successive deformation of the single rivet (unit: mm), (b) component X stress around the part hole at the end of riveting time (unit: GPa), (c) component Y stress around the part hole at the end of riveting time (unit: GPa), and (d) component Y stress around the part hole at the end of riveting time (unit: GPa)

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Fig. 3

Region specifications of the deformed rivet under the hammer impact

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Fig. 4

Dynamic analysis result for the assembly with four rivets: (a) sequential deformation steps of four rivets (unit: mm), (b) part deformation at the end of the riveting time of four rivets (unit: mm), and (c) comparison between the hourglass and internal energies in the iteration

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Fig. 5

Brief experiment information for the assembly with four rivets: (a) identity number of key points and the rivets and (b) coordinate test for the clamped assembly

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Fig. 6

Key point coordinates of the assembly with four rivets using different riveting sequences: (a) sequence 1-2-4-3, (b) sequence 1-2-3-4, (c) sequence 1-4-3-2, (d) sequence 1-4-2-3, (e) sequence 1-3-2-4, and (f) sequence 1-3-4-2

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Fig. 7

Spatial interpolation based on the inherent strain database (unit: mm): (a) spatial distribution of the node in inherent strain database and (b) coordinate conversion between nodes of the inherent strain database and the part hole

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Fig. 8

The local-to-global dimensional analysis framework for the riveted assembly

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Fig. 9

Coupled deformation of riveted parts given by the proposed approach (unit: mm)

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Fig. 10

Part label and point selection for the antisymmetric sample

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Fig. 11

Feature point vector at the mating surface: (a) ideal feature point vector and (b) tested feature point vector

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Fig. 12

The clamped experimental sample and the riveting sequence

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Fig. 13

FE model of experimental sample: (a) FEs and key points and (b) nodal components

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Fig. 14

Dimensional error induced by mating gaps

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Fig. 15

Dimensional error comparisons between the experiments and simulations: (a) key point coordinates at the initial clamped state, (b) key point coordinates without riveting sequence effect, and (c) key point coordinates considering riveting sequence effect

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Fig. 16

Relation of microrotational motions

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