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Research Papers

Stream of Variation Modeling and Analysis for Compliant Composite Part Assembly—Part I: Single-Station Processes

[+] Author and Article Information
Tingyu Zhang

School of Mechanical Engineering,
Beijing Institute of Technology,
Beijing 100081, China
e-mail: tzhang2012@hotmail.com

Jianjun Shi

Fellow ASME
H. Milton Stewart School of Industrial and Systems Engineering,
Georgia Institute of Technology,
Atlanta, GA 30332
e-mail: jianjun.shi@isye.gatech.edu

1Corresponding author.

Manuscript received May 11, 2015; final manuscript received March 24, 2016; published online July 15, 2016. Assoc. Editor: Jaime Camelio.

J. Manuf. Sci. Eng 138(12), 121003 (Jul 15, 2016) (15 pages) Paper No: MANU-15-1223; doi: 10.1115/1.4033231 History: Received May 11, 2015; Revised March 24, 2016

Composite structures are widely used due to their superior properties, such as low density, high strength, and high stiffness-to-weight ratio (Mallick, 1993, Fiber-Reinforced Composites: Materials, Manufacturing, and Design, Marcel Dekker, New York). However, the lack of methodologies for variation modeling and analysis of composite part assembly has imposed a significant constraint on developing dimensional control for composite assembly processes. This paper develops a modeling method to predict assembly deviation for compliant composite parts in a single-station assembly process. The approach is discussed in two steps: considering the part manufacturing error (PME) only and considering both the PME and the fixture position error (FPE). Finite element method (FEM) and homogenous coordinate transformation are used to reveal the impact of the PME and the FPE. The validity of the method is verified with two case studies on assembly deviation prediction of two composite laminated plates considering the PME only and both the PME and the FPE, respectively. The proposed method provides the basis for assembly deviation prediction in the multistation composite assembly.

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Figures

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Fig. 3

Assembly process considering PME only: (a) PME, (b) clamping parts to nominal position, (c) riveting two parts together, and (d) RCs and assembly springback

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Fig. 2

Fixture position error: (a) LFD and (b) HFD

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Fig. 4

Procedures of assembly deviation prediction considering both the PME and the FPE

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Fig. 5

Calculation of part deviation caused by the PME and the LFD: (a) three states of a part, (b) translation of the actual art along the z axis, (c) rotation of the shifted part around the x axis, and (d) rotation of the rotated part around the y axis

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Fig. 7

Diagram of assembly

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Fig. 9

Distribution of assembly deviation of node 21: (a) MIC for composite assembly and (b) MCS for composite assembly

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Fig. 6

Assembly process of composite laminated plates: (a) loading parts to fixtures, (b) clamping parts to nominal positions, (c) joining two parts, and (d) RCs and assembly springback

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Fig. 8

Mesh and nodes of the assembly

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Fig. 11

Deviation distribution of node 21: (a) considering PME + LFD, (b) considering PME + LFD + HFD, and (c) after assembly

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Fig. 10

Comparison of two methods for the second problem

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Fig. 12

Triangle element with three nodes

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