Variation Simulation of Compliant Metal Plate Assemblies Considering Welding Distortion

Abstract

The shipbuilding industry employs numerous cutting and joining processes to build the ship and offshore structure. Welding, as a primary joining process, inherently causes distortion and accounts for most of the major geometrical variation in the intermediate products, thus adversarially affecting the downstream assembly processes. Because of the welding process, the variation analysis of compliant assemblies in shipbuilding is clearly different from that of the automobile and aerospace industries, where the distortion during the joining process is negligible. This paper proposes a variation simulation model including the effects of joining process distortion for ships and offshore structures. The proposed model extends the concepts of the sources of variation and the Method of Influence Coefficient for a compliant mechanical assembly to include the welding distortions. The proposed model utilizes welding distortion patterns and a transformation matrix to efficiently model the deformation due to the joining process. Also the welding A c c e p t e d M a n u s c r i p t N o t C o p y e d i t e dDownloaded From: http://manufacturingscience.asmedigitalcollection.asme.org/ on 02/19/2015 Terms of Use: http://asme.org/terms Journal of Manufacturing Science and Engineering distortions are represented as stochastic values due to its randomness. The model is verified by case study simulation and by a comparison with welding experimental results.

Variation modeling and analysis with interval approach for the assembly of compliant aeronautical structures

“…Step 5. Compute the assembly variation intervals of the observation points with the obtained sensitivity matrix S using equations (13) and (16).…”

“…Furthermore, the modeling and analyzing of the variation propagation in automotive assembly are studied in the literature. 9,10 In addition, the effects on compliant assembly variation of many factors are studied, such as joint, [11][12][13][14][15] assembly sequence, [16][17][18][19] material characteristics [20][21][22] and gaps. [23][24][25] Recently, the research on variation modeling and analysis concerning compliant assembly has been extended to aircraft industry.…”

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

“…Plates. Numerous papers [2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20] can be found studying how to model assembly deviation for sheet metal assembly. Similar to sheet metal assembly, the assembly process of laminated composite plates is a type of compliant part assembly, which is comprised of four steps ( Fig.…”

“…The covariance matrix of assembly was calculated by combining principal component analysis and finite element analysis (FEA) based on the MIC model. Choi and Chung [8] extended the concepts of the sources of variation and the MIC model for a compliant mechanical assembly by utilizing the welding distortion patterns and a transformation matrix to efficiently model the deformation due to the joining process. Matuszyk et al [9] combined the point distribution modal and Kernel density estimation to provide a statistical shape model (the KDE-PDM) that can represent correlated variation modes.…”

Compliant assembly analysis including initial deviations and geometric nonlinearity—Part I: Beam structure

“…13 utilized spatial beam theory to establish a variation analysis model for fuselage digital assembly process, which was validated by an assembly case of aircraft fuselage section. Choi and Chung 14 extended MIC to shipbuilding field and presented a compliant assembly analysis method to account the welding distortion during assembly processes. Wärmefjord et al.…”