Hostname: page-component-cd9895bd7-7cvxr Total loading time: 0 Render date: 2024-12-28T15:10:52.856Z Has data issue: false hasContentIssue false
  • English
  • Français

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

Part of: Robust Design

Published online by Cambridge University Press:  26 July 2019

Hanchen Zheng ,
Frank Litwa ,
Benjamin Reese ,
Chenyang Li ,
Martin Bohn  and
Kristin Paetzold
Hanchen Zheng*
Affiliation:
Daimler AG;
Frank Litwa
Affiliation:
Daimler AG;
Benjamin Reese
Affiliation:
Dimensional Control Systems Inc.;
Chenyang Li
Affiliation:
Dimensional Control Systems Inc.;
Martin Bohn
Affiliation:
Daimler AG;
Kristin Paetzold
Affiliation:
Universität der Bundeswehr München
*
Contact: Zheng, Hanchen Daimler AG TF/VDF, Germany, hanchen.zheng@daimler.com

Abstract

Core share and HTML view are not available for this content. However, as you have access to this content, a full PDF is available via the ‘Save PDF’ action button.

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.

Keywords

Tolerance representation and managementElastic tolerance simulationDesign for X (DfX)SimulationCompliant assembly
Type
Article
Information
Proceedings of the Design Society: International Conference on Engineering Design , Volume 1 , Issue 1 , July 2019 , pp. 3461 - 3470
Creative Commons
Creative Common License - CCCreative Common License - BYCreative Common License - NCCreative Common License - ND
This is an Open Access article, distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives licence (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is unaltered and is properly cited. The written permission of Cambridge University Press must be obtained for commercial re-use or in order to create a derivative work.
Copyright
© The Author(s) 2019

References

Camelio, J.A. and Hu, S.J. (2003), “Modeling Variation Propagation of Multi-Station Assembly Systems With Compliant Parts”, Journal of Mechanical Design, Vol. 125 No. 4, pp. 673–681.10.1115/1.1631574Google Scholar
Corrado, A. and Polini, W. (2017), “A comprehensive study of analysis methods for rigid parts with manufacturing signatures and operating conditions”, Journal of Advanced Mechanical Design, System, and Manufacturing, Vol. 11 No. 2, pp. JAMDSM0017–JAMDSM0017. https://doi.org/10.1299/jamdsm.2017jamdsm0017Google Scholar
Schleich, B. and Wartzack, S. (2016), “A Quantitative Comparison of Tolerance Analysis Approaches for Rigid Mechanical Assemblies”, Procedia CIRP, Vol. 43, pp. 172–177. https://doi.org/10.1016/j.procir.2016.02.013Google Scholar
Liu, S.C. and Hu, S.J. (1997), “Variation simulation for deformable sheet metal assemblies using finite element methods”, Journal of manufacturing science and engineering, Vol. 119 No. 3, pp. 368–374.10.1115/1.2831115Google Scholar
Chang, M. and Gossard, D.C. (1997), “Modeling the assembly of compliant, non-ideal parts”, Computer-Aided Design, Vol. 29 No. 10, pp. 701–708.10.1016/S0010-4485(97)00017-1Google Scholar
Moos, S. and Vezzetti, E. (2012), “Compliant assembly tolerance analysis: guidelines to formalize the resistance spot welding plasticity effects”, The International Journal of Advanced Manufacturing Technology, Vol. 61 No. 5, pp. 503–518. https://doi.org/10.1007/s00170-011-3729-0Google Scholar
Bohn, M. and Hetsch, K. (2013), Toleranzmanagement im Automobilbau, Carl Hanser Verlag GmbH Co KG, München.10.3139/9783446435445Google Scholar
Ding, Y., Ceglarek, D. and Shi, J. (2000), “Modeling and diagnosis of multistage manufacturing processes: part I: state space model”, Proceedings of the 2000 Japan/USA symposium on flexible automation, pp. 23–26.Google Scholar
Yan, H., Wu, X. and Yang, J. (2015), “Application of Monte Carlo Method in Tolerance Analysis”, Procedia CIRP, Vol. 27, pp. 281–285. https://doi.org/10.1016/j.procir.2015.04.079Google Scholar
Gerbino, S., Patalano, S. and Franciosa, P. “Statistical variation analysis of multi-station compliant assemblies based on sensitivity matrix”, International Journal of Computer Applications in Technology, Vol. 33 No. 1, pp. 12–23.10.1504/IJCAT.2008.021881Google Scholar
Franciosa, P. (2009), Modeling and simulation of variational rigid and compliant assembly for tolerance analysis, Doctoral dissertation, Ph. D Thesis, The University Naples Federico II, Italia.Google Scholar
Chen, W., Jin, S. and Lai, X. (2014), “Tolerance Optimization Considerations Applied to the Sheet Metal Compliant Assembly”, Computer-Aided Design and Applications, Vol. 11 No. 1, pp. 68–76. https://doi.org/10.1080/16864360.2014.914413Google Scholar
Franciosa, P. (2009), Modeling and simulation of variational rigid and compliant assembly for tolerance analysis, Doctoral dissertation, Ph.D Thesis, The University Naples Federico II, Italia.Google Scholar
Chen, W., Jin, S. and Lai, X. (2014), “Tolerance Optimization Considerations Applied to the Sheet Metal Compliant Assembly”, Computer-Aided Design and Applications, Vol. 11 No. 1, pp. 68–76. https://doi.org/10.1080/16864360.2014.914413Google Scholar
Wang, H., Zhang, S. and Yu, J. (2018), “Computer Aided Tolerancing of Composite Elevator Assembly Involving Clamping Forces Coordination”, Procedia CIRP, Vol. 75, pp. 256–260. https://doi.org/10.1016/j.procir.2018.04.057Google Scholar
Barbero, B.R., Aragón, A.C. and Pedrosa, C.M. (2015), “Validation of a tolerance analysis simulation procedure in assemblies”, The International Journal of Advanced Manufacturing Technology, Vol. 76 No. 5–8, pp. 1297–1310. https://doi.org/10.1007/s00170-014-6229-1Google Scholar
Beckmann, A., Bohn, M. and Gust, P. (2015), “Tolerance Simulation in the Assembling Process based on Experimental Data from Series Production”, Procedia CIRP, Vol. 27, pp. 35–40. https://doi.org/10.1016/j.procir.2015.04.040Google Scholar
Camelio, J.A., Hu, S.J. and Marin, S.P. (2004), “Compliant Assembly Variation Analysis Using Component Geometric Covariance”, Journal of Manufacturing Science and Engineering, Vol. 126 No. 2, pp. 355–360.10.1115/1.1644553Google Scholar
Yan, Y. (2019), Neue Systematik mit erweiterten Definitionen der Bezüge und Tolerierungen für Geometrieelemente, Doctoral dissertation, Ph.D Thesis, University of Stuttgart, Germany.Google Scholar
Kaestle, C. (2016), Simulationsmethode zur Beurteilung der Maßhaltigkeit von rollgefalzten Karosseriebaugruppen im Zusammenbau, Institut für Umformtechnik, Stuttgart, Stuttgart. http://doi.org/10.18419/opus-9111Google Scholar
Wang, H. and Liu, J. (2016), “Tolerance simulation of thin-wall C-section composite beam assembling with small displacement torsor model”, Procedia CIRP, Vol. 43, pp. 274–279. https://doi.org/10.1016/j.procir.2016.02.015Google Scholar
Litwa, F., Gottwald, M., Bohn, M., Klinger, J.F., Walter, M., Wartzack, S. and Vielhaber, M. (2015), “Automated point-based tolerance analysis model creation for sheet metal parts”, Procedia CIRP, Vol. 27, pp. 65–70. https://doi.org/10.1016/j.procir.2015.04.045Google Scholar
Dimensional Control System (2008), 3DCS Compliant Modeler, Dimension Engineering News.Google Scholar
Dimensional Control System (2010), Compliant Modeling, Dimensional Engineering News.Google Scholar
Dimensional Control System (2016), Compliant Move Toolbox, Dimensional Engineering News.Google Scholar