Abstract
Part tolerances and fixture layouts are two pivotal factors in the geometrical quality of a compliant assembly. The independent design and optimization of these factors for compliant assemblies have been thoroughly studied. However, this paper presents the dependency of these factors and, consequently, the demand for an integrated design of them. A method is developed in order to address this issue by utilizing compliant variation simulation tools and evolutionary optimization algorithms. Thereby, integrated and non-integrated optimization of the tolerances and fixture layouts are conducted for an industrial sample case. The objective of this optimization is defined as minimizing the production cost while fulfilling the geometrical requirements. The results evidence the superiority of the integrated approach to the non-integrated in terms of the production cost and geometrical quality of the assemblies.
Highlights
Geometrical variation is an inevitable consequence of the mass production of physical products
These data include the non-nominal geometry of produced parts, available measurement data of produced parts, and predictability of the deformed forms that result from different production processes
Each scenario results in different geometrical quality and production costs
Summary
Geometrical variation is an inevitable consequence of the mass production of physical products. Geometrical tolerances and the fixture layout are two main factors in defining the geometrical quality of sheet metal assemblies. Determining their optimal design is crucial in the development of these products. The presented method leverages from the opportunity that is provided by available data in the new industrial era, i.e., Industry 4.0 [3]. These data include the non-nominal geometry of produced parts, available measurement data of produced parts, and predictability of the deformed forms that result from different production processes
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