Prediction and minimization of excessive distortions and residual stresses in compliant assembled structures




Yoshizato, Anderson

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The procedure of joining flexible or nonrigid parts using applied loads is called compliant assembly, and it is widely used in automotive, aerospace, electronics, and appliance manufacturing. Uncontrolled assembly processes may produce geometric errors that can exceed design tolerances and induce an increment of elastic energy in the structure due to the accumulation of internal stresses. This condition might create unexpected deformations and residual stress distributions across the structure that compromise product functionality. This thesis presents a method based on nonlinear Finite Element Analysis (FEA), metamodelling, and optimization techniques to provide accurate and on-time shimming strategies to support the definition of optimum assembly strategies. An example of the method on a typical aerospace wing box structure is demonstrated in the present study. The delivered outputs intend to support the production line by anticipating the response of the structure under a specific assembly condition and presenting alternative assembly strategies that can be applied to address eventual predicted issues on product requirements.



Compliant Assembly, Assembly Simulation, Residual Stress Assembly, Distortions Assembly, Deformation Assembly, Distortions Wing, Finite Element Analysis Assembly, FEA Assembly, FEM Assembly, Assembled Structures, Assembly Optimization, Assembly Metamodelling, Assembly Surrogate Model, Shimming Assembly, Shims Assembly, Simulation of Manufacturing Process, Tolerance allocation, Tolerance Analysis