Integrated Tolerance and Fixture Layout Design for Compliant Sheet Metal Assemblies

Aderiani, Abolfazl Rezaei; Hallmann, Martin; Wärmefjord, Kristina; Schleich, Benjamin; Söderberg, Rikard; Wartzack, Sandro

doi:10.3390/app11041646

Cited by 9 publications

(3 citation statements)

References 44 publications

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“…In this framework, Miah et al (2022) developed a tolerance optimization method for aircraft product assembly based on the assembly accuracy constrain, precession constrain and the total production cost of the assembly product. Besides, lots of tolerance allocation methods were proposed in the past several decades for both the machining parts and sheet metal parts (Rezaei Aderiani et al, 2021).…”

Section: Overview On Tolerance Allocation For Manufacturingmentioning

confidence: 99%

An integrated hybrid approach for assembly tolerance transfer and allocation

Ghali,

Aifaoui

2024

RIA

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Purpose This study aims to develop an optimal tolerance allocation strategy involves integrating the unique transfer (UT) approach and the difficulty coefficient evaluation (DCE) routine in an interactive hybrid method. This method combines the strengths of both UT and DCE, ensuring simultaneous utilization for enhanced performance. The proposed tolerancing model manifests an integrated computer-aided design (CAD) tool. Design/methodology/approach By combining UT and DCE based on failure mode, effects and criticality analysis (FMECA) tool and the Ishikawa diagram, the proposed collaborative hybrid tool ensures an efficient and optimal tolerance allocation approach. The integration of these methodologies not only addresses specific transfer challenges through UT but also conducts a thorough evaluation of difficulty coefficients via DCE routine using reliability analysis tools as FMECA tool and the Ishikawa diagram. This comprehensive framework contributes to a robust and informed decision-making process in tolerance allocation, ultimately optimizing the design and manufacturing processes. Findings The presented methodology is implemented with the aim of generating allocated tolerances that align with specific difficulty requirements, facilitating the creation of a mechanical assembly characterized by high quality and low cost. To substantiate and validate the conceptual framework and methods, an integrated tool has been developed, featuring a graphical user interface (GUI) designed in MATLAB. This interface serves as a platform to showcase various interactive and integrated tolerance allocation approaches that adhere to both functional and manufacturing prerequisites. The proposed integrated tool, designed with a GUI in MATLAB, offers the capability to execute various examples that effectively demonstrate the benefits of the developed tolerance transfer and allocation methodology. Originality/value The originality of the proposed approach is the twining between the UT and DCE simultaneous in an integrated and concurrent tolerance transfer and allocation model. Therefore, the proposed approach is named an integrated CAD/tolerance model based on the manufacturing difficulty tool. The obtained results underscore the tangible advantages stemming from the integration of this innovative tolerance transfer and allocation approach. These benefits include a notable reduction in total cost and a concurrent enhancement in product quality.

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Section: Overview On Tolerance Allocation For Manufacturingmentioning

confidence: 99%

An integrated hybrid approach for assembly tolerance transfer and allocation

Ghali,

Aifaoui

2024

RIA

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“…Besides the aforementioned differences in locating principles, the "N-2-1"or "X-2-1" fixturing schemes with inherent multidimensional or dynamic variables make the decision making of the locator layout (i.e., location and number of locators) especially troublesome. The first difficulty is that there does not always exist an analytical or form-closed expression between the fixture layout and the concerned workpiece deformations under the actions of manufacturing process loads such as assembly loading or machining forces [8]. Therefore, most researchers have formulated optimization models of multipoint fixture layouts to achieve the minimum workpiece deformation and computed the deflection under different fixture layouts by the finite element method (FEM).…”

Section: Introductionmentioning

confidence: 99%

Digital Twin-Driven Reconfigurable Fixturing Optimization for Trimming Operation of Aircraft Skins

2022

Aerospace

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The incomplete constraint induced by multipoint reconfigurable fixturing and the inherently weak rigidity of thin shell parts significantly hinder the stability of flexible fixturing systems. In particular, during the trimming operation, the number of effective locators may change with the progressive separation of the desired shape from that of the blank part, which easily produces the cliff effect (instantaneous dramatic reduction) of the system stiffness. As a result, the location layout becomes a main crux in reality. Regarding this issue, the author herein presents a digital twin-based decision-making methodology to generate reconfigurable fixturing schemes through integrating virtual and physical information. Considering the intrinsic features of the trimming process, such as the time-varying propagation of the system stiffness and the coupling effects of multiattribute process parameters, the hidden Markov model was introduced to cope with reconfigurable fixturing optimization. To achieve fast convergence and seek a feasible solution, local information (where low system rigidity occurs) was extracted and shared to guide the optimization process in a front-running simulation. To demonstrate the presented method, trimming experiments were performed on a large-size compliant workpiece held by a reconfigurable fixturing system that was developed independently by our research group. The experimental results indicate that the proposed method could adaptively iterate out the optimal locating schema and process control reference from the virtual fixturing and trimming simulation to guarantee the time-varying stability of the trimming process in the real world. Clearly, the digital twin-based reconfigurable fixturing planning approach generated a high possibility of building a context-specific, closed-loop decision-making paradigm and allowing the reconfigurable fixturing system to behave in a more adaptable and flexible manner.

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“…For instance, the LMM was only used for simple products [1,8,42,43], which have only two mating components. Several works have been reported on finding the optimum allocated tolerance values for the components of complex assembly [44][45][46][47][48][49][50][51]. A limited number of authors have concentrated on non-linear assembly products that consist of more than two components [20,26,38].…”

Section: Introductionmentioning

confidence: 99%

A Novel Methodology for Simultaneous Minimization of Manufacturing Objectives in Tolerance Allocation of Complex Assembly

et al. 2021

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Tolerance cost and machining time play crucial roles while performing tolerance allocation in complex assemblies. The aim of the proposed work is to minimize the above-said manufacturing objectives for allocating optimum tolerance to the components of complex assemblies, by considering the proper process and machine selections from the given alternatives. A novel methodology that provides a two-step solution is developed for this work. First, a heuristic approach is applied to determine the best machine for each process, and then a combined whale optimization algorithm with a univariate search method is used to allocate optimum tolerances with the best process selection for each sub-stage/operation. The efficiency of the proposed novel methodology is validated by solving two typical tolerance allocation problems of complex assemblies: a wheel mounting assembly and a knuckle joint assembly. Compared with previous approaches, the proposed methodology showed a considerable reduction in tolerance cost and machining time in relatively less computation time.

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Integrated Tolerance and Fixture Layout Design for Compliant Sheet Metal Assemblies

Cited by 9 publications

References 44 publications

An integrated hybrid approach for assembly tolerance transfer and allocation

An integrated hybrid approach for assembly tolerance transfer and allocation

Digital Twin-Driven Reconfigurable Fixturing Optimization for Trimming Operation of Aircraft Skins

A Novel Methodology for Simultaneous Minimization of Manufacturing Objectives in Tolerance Allocation of Complex Assembly

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