An approach to evaluating product assembly precision considering the effect of joint surface deformation

Lu, Cong; Wang, Songling

doi:10.1177/0954406213519758

Cited by 13 publications

(6 citation statements)

References 19 publications

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“…Jayaprakash et al (2014) developed a FEM model for a motor assembly to determine the deformation of various parts due to the influence of inertia effects and temperature change and integrated the deformations into tolerance design. Lu and Wang (2014) proposed an approach to evaluating the product assembly precision in different assembly sequences, considering the effect of joint surface deformation under different assembly conditions and different parameters of the joint surface based on finite element analysis. Guo et al (2016) proposed a method using FEM to calculate the assembly variation propagation of 3D assemblies considering geometric variation and part deformation.…”

Section: Introductionmentioning

confidence: 99%

Assembly variation analysis of the non-rigid assembly with a deformation gradient model

Ajani

2021

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Purpose This paper aims to develop a mathematical method to analyze the assembly variation of the non-rigid assembly, considering the manufacturing variations and the deformation variations of the non-rigid parts during the assembly process. Design/methodology/approach First, this paper proposes a deformation gradient model, which represents the deformation variations during the assembly process by considering the forces and the self-weight of the non-rigid parts. Second, the developed deformation gradient models from the assembly process are integrated into the homogenous transformation matrix to model the deformation variations and manufacturing variations of the deformed non-rigid part. Finally, a mathematical model to analyze the assembly variation propagation is developed to predict the dimensional and geometrical variations due to the manufacturing variations and the deformation variations during the assembly process. Findings Through the case study with a crosshead non-rigid assembly, the results indicate that during the assembly process, the individual deformation values of the non-rigid parts are small. However, the cumulative deformation variations of all the non-rigid parts and the manufacturing variations present a target value (w) of −0.2837 mm as compared to a target value of −0.3995 mm when the assembly is assumed to be rigid. The difference in the target values indicates that the influence of the non-rigid part deformation variations during the assembly process on the mechanical assembly accuracy cannot be ignored. Originality/value In this paper, a deformation gradient model is proposed to obtain the deformation variations of non-rigid parts during the assembly process. The small deformation variation, which is often modeled using a finite-element method in the existing works, is modeled using the proposed deformation gradient model and integrated into the nominal dimensions. Using the deformation gradient models, the non-rigid part deformation variations can be computed and the accumulated deformation variation can be easily obtained. The assembly variation propagation model is developed to predict the accuracy of the non-rigid assembly by integrating the deformation gradient models into the homogeneous transformation matrix.

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Section: Introductionmentioning

confidence: 99%

Assembly variation analysis of the non-rigid assembly with a deformation gradient model

Ajani

2021

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“…Then, the accuracy of this model was demonstrated with a panel through the finite element analysis. Lu and Wang 25 considered the deformation of the joint surface in different assembly sequences, and proposed a method to evaluate the assembly quality of the product. It was found that the compliant joint deformation affects the final assembly precision and should be investigated further under different machining methods.…”

Section: Introductionmentioning

confidence: 99%

Assembly research of aero-engine casing involving bolted connection based on rigid-compliant coupling assembly deviation modeling

Kang

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Assembly analysis is necessary for mechanical product to optimize design and improve the product quality since assembly deviation is the key factor affecting the assembly quality. In this paper, the rigid-compliant assembly of thin-walled aero-engine casing is studied to evaluate the assembly quality at the design stage. First, the Jacobian–Torsor model is proposed to construct multistage casing assembly owing to its effectiveness to express assembly deviation. The torsor expression is modified and expanded to present the rigid-compliant coupling tolerance. Then, the partial parallel chain is addressed via combination operation. By using extremum and statistical method, the tolerance zone and the distribution of the objective deviation are obtained. Furthermore, to study the effect of specified compliant deviation on statistical distribution, the bolt looseness and positional deformation are investigated to provide an effective means for geometric deviation and connecting joints of aero-engine casing components of precision assembly. The presented method can address compliant deformation tolerance and geometrical manufacturing tolerance together, and is reliable for casing assembly to predict assembly quality at the design stage. In addition, it also has a great significance to guide tolerance design and product optimization.

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“…11 proposed a method to improve the accuracy of the machine tool assembly by considering the deformation of the joint surface and using the antideformation principle. Lu 12 studied the accuracy of the basic parameters of the joint surface on the precision of a CNC machine tool assembly and used a neural network model to predict the final possible assembly accuracy, and found the best assembly sequence. Although these studies considered the joint-surface error as an error source in the machine tool assembly, the roller guide error was less studied.…”

Section: Introductionmentioning

confidence: 99%

A linear model for the machine tool assembly error prediction considering roller guide error and gravity-induced deformation

Shi

Guo

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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In assembly, error prediction and control according to the error state of the machine parts are the key links to ensuring the accuracy of the entire machine tool. In this study, an assembly error modeling method considering the error of the roller guide and gravity-induced deformation is proposed. First, based on the Hertz contact theory, a nonlinear error propagation model for the roller guide to the moving part is proposed. With this model, the analytical relationship between the straightness error of the guide rail and the errors of the moving part can be established. Then, after the linearization of the guide error model, a machine assembly error model considering the guide error is proposed. This model expresses the linear relationship between the error of the rolling joint surface and the error of the machine tool after the final assembly. Additionally, considering the influence of gravity deformation of structural parts, the gravity deformation is extracted by the finite element analysis method and added to the model by linear superposition. As a result, the model corresponds more with the practical assembly process. Finally, an assembly error prediction method of the precision horizontal machining center is presented, and a case is studied to demonstrate the validity of the proposed model and method.

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An approach to evaluating product assembly precision considering the effect of joint surface deformation

Cited by 13 publications

References 19 publications

Assembly variation analysis of the non-rigid assembly with a deformation gradient model

Assembly variation analysis of the non-rigid assembly with a deformation gradient model

Assembly research of aero-engine casing involving bolted connection based on rigid-compliant coupling assembly deviation modeling

A linear model for the machine tool assembly error prediction considering roller guide error and gravity-induced deformation

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