An investigation of compliant parts deformation during handling operations

Abstract

Compliant parts are widely used in Ship building, Automotive and Aerospace industries. One of the critical issues in the material handling of compliant part is excessive part deformation. The deformation of compliant sheet metal parts during the handling process can significantly impact on products' dimensional quality and shape variation. Even the compliance of large sheet-metal part can cause permanent deformation during the handling. Purpose of this research is to investigate the compliant parts deformation and define best holding end-effecter layouts which give the minimum deformation during handling operations. Finite Element Analysis (FEA) techniques were used to investigate the compliant parts deformation by varying the holding end effecter layout during handling operations. A series of experimental trials were performed using sheet metal parts which are widely used in ship building industries. Experimental data were compared with FEA results to validate the FEA model. Based on research outcome a formula was derived which can be used to find the minimum deformation for rectangular shape compliant parts. A set of guidelines were developed for industries to predict the amount of deformation when using different end effecter layouts. Methodology developed through this research could be used by industries to handle the compliant parts with minimum deformation and without changing material properties. This research further influences the sheet metal handling industries to increase their quality and productivity while reducing scrap rate.