Research Papers

Stream of Variation Modeling and Analysis for Compliant Composite Part Assembly— Part II: Multistation 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 March 24, 2016; final manuscript received March 25, 2016; published online July 19, 2016. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 138(12), 121004 (Jul 19, 2016) (15 pages) Paper No: MANU-16-1179; doi: 10.1115/1.4033282 History: Received March 24, 2016; Revised March 25, 2016

Part I of this paper (Zhang and Shi, 2015, “Stream of Variation Modeling and Analysis for Compliant Composite Part Assembly—Part I: Single-Station Processes,” ASME J. Manuf. Sci. Eng.,) has studied the variation modeling and analysis of compliant composite part assembly in a single-station process. In practice, multiple assembly stations are involved in assembling the final product. This paper aims to develop a variation propagation model for stream of variation analysis in a multistation assembly process for composite parts. This model takes into account major variation factors, including part manufacturing error (PME), fixture position error (FPE), and relocation-induced error (RIE). With the help of a finite element method (FEM), a state space model (SSM) is established to represent the relationships between the sources of variation and the final assembly variation. The developed methodology is illustrated by using a case study of three composite laminated plates assembled in a two-station assembly system. The validity of the developed SSM is verified by Monte Carlo simulation (MCS), which is implemented on the basis of FEM. The SSM provides a potential application for diagnosis of variation sources and variation reduction.

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Fig. 1

Definition of the RIE

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Fig. 2

Assembly process of three parts in a two-station assembly process. (a) Station 1: locating parts to fixtures, (b) station 1: clamping parts to nominal position, (c) station 1: joining two parts together, (d) station 1: releasing clamps and assembly springback, (e) station 1: releasing locators and assembly springback, (f) station 2: relocating subassembly at the nominal locating fixtures, (g) station 2: locating a subassembly and a part to the actual fixtures, (h) station 2: clamping a subassembly and a part to the nominal position, (i) station 2: joining a subassembly and a part together, (j) station 2: releasing clamps and assembly springback, and (k) station 2: releasing locators and assembly springback.

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Fig. 3

Illustration of (a) variation propagation in a multistation assembly process and (b) variation propagation in assembly station k

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Fig. 4

Diagram of an assembly process: (a) station 1 and (b) station 2

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Fig. 5

Deviation distribution of all the MPs in the overall assembly process: (a) MP11 before station 2, (b) MP21 before station 2, (c) MP11 after station 2, (d) MP21 after station 2, and (e) MP31 after station 2

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Fig. 6

Procedures of the MCS: (a) the procedures of calculating the assembly deviation with ansys and (b) details of the calculation of the output results specified in Fig. 6(a)

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Fig. 7

Deformation deviation of the assembly in the overall assembly process: (a) station 1 and (b) station 2




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