Compliant assembly tolerance analysis: guidelines to formalize the resistance spot welding plasticity effects

Moos, Sandro; Vezzetti, Enrico

doi:10.1007/s00170-011-3729-0

Cited by 20 publications

(13 citation statements)

References 31 publications

(59 reference statements)

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“…At the same time, the finite element method (FEM) was also applied in the tolerance analysis. For example, Liu and Hu (1997) developed the method of influence coefficient (MIC) to simulate compliant sheet metal assemblies, Chang and Grssard (1997) proposed PCFR (Positioning, Clamping, Fastening and Releasing) cycle to model the assembly of compliant parts, butt joint and a slip joint in a body in white (BIW) process are analyzed in the work of Moos and Vezzetti (2012). However, the conventional statistical tolerance simulation results has a shortage in fitting to the real manufacturing processes.…”

Section: Tolerance Analysis In Automobile Processesmentioning

confidence: 99%

A Modeling Approach for Elastic Tolerance Simulation of the Body in White Hang-On Parts

Zheng

Litwa

Reese

et al. 2019

Proc. Int. Conf. Eng. Des.

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Computer aided tolerancing (CAT) in the automobile industry is implemented by CAD tools. These tools analyze the manufacturability of complex assemblies with rigid single parts in an early stage to reduce the product development time and the cost for hardware prototypes. This paper proposes an approach to implement tolerance simulation for a compliant assembly, which includes manufacturing processes such as clinching, bolting and hemming by applying tolerance simulation tool. The fender- BIW system is simulated as a compliant–rigid system and the simulation model is applied to two production scenarios. The simulation results are compared with real measurement data, which demonstrates the efficacy of using simulation in early production as opposed to prototyping or other methods of design by showing the strong correlation between simulation results and as-built products.

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Section: Tolerance Analysis In Automobile Processesmentioning

confidence: 99%

A Modeling Approach for Elastic Tolerance Simulation of the Body in White Hang-On Parts

Zheng

Litwa

Reese

et al. 2019

Proc. Int. Conf. Eng. Des.

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“…As a further description of the result in [9], for a butt joint with a tolerance interference condition that hinders the correct loading on fixture, in figure 1 have been reproduced the total elastic strain energy density field after the clamps and the electrodes closure (fig. 1a), after the thermal cycle (fig.…”

Section: Introductionmentioning

confidence: 95%

“…The previous work of Moos et al [9] showed that, starting from welding flanges which are subjected to tolerances, the weldgun closure can cause relative sliding motion between the two flanges that are made permanent by the weld spot and that the deformations imposed by fixtures and electrodes before the weld cycle, also cause plasticization away from the welding spot, near bending fillets and locators. The comparison of the spingback of a butt joint calculated with the same boundary conditions, changing only the material model form elastic to plastic, also showed completely different behaviors.…”

Section: Introductionmentioning

confidence: 99%

An integrated strategy for variational analysis of compliant plastic assemblies on shell elements

Moos

Vezzetti

2013

Int J Adv Manuf Technol

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The variational analysis on compliant assembly has been shown to be significantly influenced by plastic deformation of the part's material induced by resistance spot welding and fixturing.The aim of this paper is to define the FEM methods required to translate the complex interaction best described by a coupled thermo-electrical-mechanical simulation with solid elements to a shell model suitable for variational analysis.The methods are here described and implemented into FEM run-time routines to be later used for the calculation of the influence coefficient matrixes and Monte-Carlo simulation, so to reduce the problem complexity.The methods tested on the geometry of a butt joint are in good agreement with the results of more traditional FEM setup and reduce the computational effort for the variational analysis.

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“…The purpose of these spot welds is to lock the geometry when the parts are being released from the fixture. The sequence in which these points are being set has a significant effect on the final geometrical outcome [3]. In Fig.…”

Section: Introductionmentioning

confidence: 99%

A new surrogate model–based method for individualized spot welding sequence optimization with respect to geometrical quality

Tabar

Wärmefjord

Söderberg

2019

Int J Adv Manuf Technol

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In an individualized shee metal assembly line, form and dimensional variation of the in-going parts and different disturbances from the assembly process result in the final geometrical deviations. Securing the final geometrical requirements in the sheet metal assemblies is of importance for achieving aesthetic and functional quality. Spot welding sequence is one of the influential contributors to the final geometrical deviation. Evaluating spot welding sequences to retrieve lower geometrical deviations is computationally expensive. In a geometry assurance digital twin, where assembly parameters are set to reach an optimal geometrical outcome, a limited time is available for performing this computation. Building a surrogate model based on the physical experiment data for each assembly is time-consuming. Performing heuristic search algorithms, together with the FEM simulation, requires extensive evaluations times. In this paper, a neural network approach is introduced for building surrogate models of the individual assemblies. The surrogate model builds the relationship between the spot welding sequence and geometrical deviation. The approach results in a drastic reduction in evaluation time, up to 90%, compared to the genetic algorithm, while reaching a geometrical deviation with marginal error from the global optimum after welding in a sequence.

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Compliant assembly tolerance analysis: guidelines to formalize the resistance spot welding plasticity effects

Cited by 20 publications

References 31 publications

A Modeling Approach for Elastic Tolerance Simulation of the Body in White Hang-On Parts

A Modeling Approach for Elastic Tolerance Simulation of the Body in White Hang-On Parts

An integrated strategy for variational analysis of compliant plastic assemblies on shell elements

A new surrogate model–based method for individualized spot welding sequence optimization with respect to geometrical quality

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