A computer-aided tool to quickly analyse variabilities in flexible assemblies in different design scenarios

In automotive and aeronautic fields, controlling the final shape of flexible assemblies (with sheet metal parts) is a key issue. Even assuming as known the shape errors in single manufactured parts, the assembly process can cause wide variability due to their flexibility and to the choice of fixtures and clamps as well as to the fastening technique adopted. Here it is strategic to analyse different assembly configurations at the beginning of the design phase and chose the one that assures less variability on the key characteristics to be achieved. This paper presents a FEM-based computer tool able to statistically analyse variations occurring in assembly processes of flexible parts. After assigning fixtures, clamping points, fastening joints and assembly sequence, the tool quickly outputs the statistical variability of the key characteristics. It is so possible to span a variety of design solutions predicting failures and controlling final variations. A case study will show how it works.