Abstract
A preeminent factor in the geometrical quality of a compliant sheet metal assembly is the fixture layout that is utilized to perform the assembly procedure. Despite the presence of a great number of studies about the optimization of assembly fixture layouts, there is not a comprehensive algorithm to optimize all design parameters of fixture layouts for compliant sheet metal assemblies. These parameters are the location and type of hole and slot in each part, the slot orientation, and the number and location of additional clamps. This paper presents a novel optimization method that optimizes all these parameters simultaneously to maximize the geometrical quality of the assemblies. To attain this goal, compliant variation simulations of the assemblies are utilized along with evolutionary optimization algorithms. The assembly springback and contacts between parts are considered in the simulations. After determining the optimal design parameters, the optimal positions of locators are fine-tuned in another stage of optimization. Besides, a top-down design procedure is proposed for applying this method to multi-station compliant assemblies. The presented method is applied to two industrial sample cases from the automotive industry. The results evidence a significant improvement of geometrical quality by utilizing the determined fixture layout from the presented method compared with the original fixture layouts of the sample cases.
Highlights
Geometrical variations are inevitable consequences of mass production
This springback and the geometrical quality of the assembly can be predicted by compliant variation simulation of the assembly procedure
Most of the presented methods for compliant assemblies are limited to assemblies in which the assembly can be mapped to a 2D surface or the design space is limited to fine-tuning the predefined area for each location. This paper addresses these gaps by presenting a novel method of design and optimization of compliant assembly fixtures
Summary
Geometrical variations are inevitable consequences of mass production. These variations can cause both aesthetic and functional problems in addition to the combined quality cost of repairs, reworks, scraps, etc., that they impose on theInt J Adv Manuf Technol (2020) 110:2181–2201 production. Geometrical variations are inevitable consequences of mass production. These variations can cause both aesthetic and functional problems in addition to the combined quality cost of repairs, reworks, scraps, etc., that they impose on the. Spot-welded sheet metal assemblies are the dominant types of assemblies in the automotive industry [2]. The spot welding is performed and the assembly is released from the fixture At this stage, springback can occur in the assembly because of implied stresses during the clamping and welding procedures. Springback can occur in the assembly because of implied stresses during the clamping and welding procedures This springback and the geometrical quality of the assembly can be predicted by compliant variation simulation of the assembly procedure
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
