Hybrid Nonlinear Variation Modeling of Compliant Metal Plate Assemblies Considering Welding Shrinkage and Angular Distortion

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Changhui Liu ◽  
Tao Liu ◽  
Juan Du ◽  
Yansong Zhang ◽  
Xinmin Lai ◽  
...  
Keyword(s):  
Geometric Nonlinearity ◽  
Angular Distortion ◽  
Assembly Process ◽  
Seam Welding ◽  
Nonlinear Variation ◽  
Metal Plates ◽  
Proposed Model ◽  
Aerospace Assembly ◽  
Assembly Deviation ◽  
Variation Model

Abstract Ship assembly involves thousands of large dimensional compliant metal plates. These compliant metal plates are fully welded together by seam welding in the assembly process. Different from the automobile and aerospace assembly process, the final variation of ship assembly is significantly influenced by the geometric nonlinearity and welding deformation generated during the seam welding process. This paper develops a nonlinear variation model (NVM) to consider the geometric nonlinearity, welding shrinkage, and angular distortion based on elastic mechanics. Furthermore, the nonlinear variation model is calibrated by the composite Gaussian process (CGP) to compensate for other factors that are not considered in the nonlinear variation model. The proposed model is validated by a case study on the deviation prediction of an assembly of two compliant metal plates and compared with the existing methods. The results show that the proposed model has a significant improvement in prediction accuracy of assembly deviation.

scholarly journals Design of on-line system for measuring and tracking time of assembly

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
Katarína Senderská ◽  
Albert Mareš ◽  
Emil Evin
Keyword(s):  
Assembly Process ◽  
Manual Assembly ◽  
Line System ◽  
Proposed Model ◽  
On Line ◽  
Tracking Time ◽  
Work Done ◽  
Line Analysis

Abstract Manual assembly performed at assembly workstations nowadays still has a unique place in different kinds of production. To increase the productivity and quality of manual assembly it is necessary to analyse the existing workplaces and find ways to improve and streamline work done at these workplaces. The article deals with the design of a model for on-line analysis of a manual assembly process. The proposed model is based on the use of sensors or the so-called button-box and the use of software for recording and evaluating data. Based on the obtained data it is then possible to evaluate the time characteristics of the assembly process, aswell as to find sources of delays and mistakes and then take appropriate action to correct them.

Evaluation Method of Assembly Yield in Three-Dimension Single-Station Assembly Process Based on Number-Theoretical Net and 3DCS

2013 ◽  
Vol 579-580 ◽  
pp. 270-275
Author(s):  
Ze Jun Wen ◽  
Fan Zhang ◽  
Jia Hu
Keyword(s):  
Evaluation Method ◽  
Three Dimensional ◽  
Total Sample ◽  
Three Dimension ◽  
Assembly Process ◽  
Variation Propagation ◽  
Single Station ◽  
Net Method ◽  
Component Assembly ◽  
Assembly Deviation

Evaluation method of assembly yield in three-dimension single-station assembly process is presented based on Number-Theoretical Net (NT-net) and 3DCS. Firstly, based on the analysis of fixture deviation affect assembly deviation under arbitrary layout, the three dimensional single-station assembly deviation model under arbitrary layout is developed. Then, the principle of generating good lattice point (GLP) based on NT-net method is introduced. Afterwards, taking fixture locating variations which are sampled using NT-net method for input vectors, the samples are substituted into assembly deviation model of dimension variation propagation in single-station assembly processes to get output vectors. The statistics for qualified sample is accomplished, after comparing output vectors with the variations of measuring points on component. Assembly yield in three-dimension single-station assembly processes is gained when qualified sample divided by total sample. Finally, a real case in sheet metal assembly is given as an example to calculate the assembly yield in three-dimension single-station assembly processes. The result is validated by 3DCS.

A New Approach for Determining Bolt Load of Eccentric Bolted Joints

2014 ◽  
Vol 668-669 ◽  
pp. 115-118
Author(s):  
Xi Wang Wang ◽  
Xiao Yang Li ◽  
Xiao Guang Wang ◽  
Lin Lin Zhang
Keyword(s):  
Fatigue Loading ◽  
Bolted Joints ◽  
Bolted Joint ◽  
Bolted Connection ◽  
New Approach ◽  
Nonlinear Variation ◽  
Linear Elastic ◽  
Proposed Model ◽  
Service Load ◽  
Interface Contact

Bolt load in a bolted connection directly influence the safety of a design in regard to both static and fatigue loading as well as in the prevention of separation in the connection. When the separating force is applied off the bolt center, although the materials for the bolted joint remain in the linear elastic range, the interface contact area between the clamped plates is sensitive to both the magnitude and the location of the separating force. This often causes nonlinear variation of the bolt load, the deformation etc. An analytical model is proposed to obtain the expression for the nonlinear bolt load under a separating service load. Finite element modeling is used for evaluating the accuracy of the proposed model.

scholarly journals Accuracy Simulation Method Based on Assembly Process Information Mapping

2018 ◽  
Vol 213 ◽  
pp. 01006
Author(s):  
Jianjun Tang ◽  
Haitao Liu
Keyword(s):  
Model Building ◽  
Simulation Method ◽  
Connection Form ◽  
Transfer Model ◽  
Assembly Process ◽  
Process Information ◽  
Assembly Accuracy ◽  
Product Manufacturing ◽  
Assembly Deviation ◽  
Deviation Vector

Assembly process information has a direct impact on product manufacturing accuracy. In order to accurately predict product accuracy, a simulation method based on assembly process information mapping was proposed. The assembly deviation information was expressed as the in-part deviation reference, feature deviation Vector direction, feature deviation vector size, deviation transmission connection form between the parts and the deviation transmission direction, and so on. The mapping between the assembly process information and the deviation transmission information was established. Then the assembly accuracy simulation algorithm including the main algorithm and assembly deviation transfer model building algorithm was established. Taking C919 internal flap assembly as an example, the effectiveness of this method had been verified.

Tolerance Analysis and Diagnosis Model of Compliant Block Assembly Considering Welding Deformation

2015 ◽  
Author(s):  
Junghyun Lee ◽  
Wooyoung Choi ◽  
Minseok Kang ◽  
Hyun Chung
Keyword(s):  
Tolerance Analysis ◽  
Normal Equation ◽  
Welding Distortion ◽  
Assembly Process ◽  
Accuracy Control ◽  
Mechanical Assembly ◽  
Multi Stage ◽  
Proposed Model ◽  
Diagnosis Model ◽  
Welding Processes

This paper proposes a simplified tolerance analysis and diagnosis model including the effects of welding distortion, for accuracy control in ship block assembly processes. The variation simulation model for tolerance analysis utilizes the concepts of the sources of variation and the compliant mechanical assembly model to include the welding distortions. The proposed model utilizes welding distortion patterns and a transformation matrix to efficiently model the deformation during the joining process. The diagnosis model assumes the multi-stage assemblies and that the variations of previous stages are propagated to the current stage. It calculates the sensitivity; a linear mapping from input parts to output assembly variations, and includes the effects of welding distortion as an additional vector that deviates the assembly variation further. The diagnosis model predicts the quantitative effect of each source of variations to the final assembly’s geometrical variation, based on normal equation and assembly stage’s state space equation model. The proposed model is applied to a realistic block assembly process for validation purpose. The model can effectively simulate the propagation of welding distortion as well as quantitatively identify variation patterns and welding processes throughout the multi-stage assembly process.

scholarly journals Analytical Model for Angular Distortion in Multilayer Welding under Constraints

2020 ◽  
Vol 10 (5) ◽  
pp. 1848
Author(s):  
Woo-Jae Seong ◽  
Sang-Cheol Park ◽  
Hee-Keun Lee
Keyword(s):  
Analytical Model ◽  
Deformation Mechanism ◽  
Angular Distortion ◽  
Welding Deformation ◽  
Butt Joints ◽  
Butt Welding ◽  
Welding Joint ◽  
Proposed Model ◽  
Welding Sequences ◽  
Fast Prediction

We propose an analytical model for the fast prediction of angular distortion that is caused by practical multilayer (or multi-pass) butt welding under constraints. To this end, the relationships between angular distortion, bead size, thickness, and degree of constraint are derived by analyzing the welding deformation mechanism and considering the bead-on-plate welding experimental results. Prediction curves are then obtained while considering the geometry of the butt welding joint. We verify the formulas through experiments under various constraint conditions, with different welding joint geometries, heat inputs, and thicknesses. The proposed model can not only predict angular distortion in butt joints of various shapes, but also allows for providing restraint methods and welding sequences for minimizing distortion.

Cooling Effects in Laser Forming

2010 ◽  
Vol 663-665 ◽  
pp. 58-63 ◽  
Author(s):  
Hong Shen ◽  
Jun Hu ◽  
Zheng Qiang Yao
Keyword(s):  
Waiting Time ◽  
Moving Boundary ◽  
Cooling System ◽  
Laser Forming ◽  
Water Cooling ◽  
Steep Temperature Gradient ◽  
Metal Plates ◽  
Proposed Model ◽  
Cooling Effects ◽  
Time Required

In the laser forming of metal plates, there is a substantial waiting time required for cooling down the workpiece so that a steep temperature gradient can be reestablished during the next scan. Currently, there are no standard techniques that can be used to reduce this waiting time. This paper discusses the possibility of using non-natural cooling systems to cool down the workpiece. A numerical model of thermo-mechanical analyses with moving boundary conditions to simulate the traveling of laser beam and moving forced water cooling system is presented. Based on the proposed model, cooling effects under different laser powers and scanning velocities with various cooling conditions are investigated. The results show that the forced water cooling can significantly reduce the temperature with no adverse effect on the forming of plates.

Effect of Activated TIG Flux on Performance of Dissimilar Welds between Mild Steel and Stainless Steel

2011 ◽  
Vol 479 ◽  
pp. 74-80 ◽  
Author(s):  
Cheng Hsien Kuo ◽  
Kuang Hung Tseng ◽  
Chang Pin Chou
Keyword(s):  
Stainless Steel ◽  
Angular Distortion ◽  
Width Ratio ◽  
Surface Appearance ◽  
Dissimilar Welds ◽  
Metal Plates ◽  
Weld Defect ◽  
Weld Depth ◽  
Oxide Flux ◽  
Powdered Form

The purpose of the present work was to investigate the effect of oxide fluxes on surface appearance, weld morphology, angular distortion, and weld defect obtained with activated tungsten inert gas (TIG) process applied to the welding of 6 mm thick dissimilar metal plates between JIS G3131mild steel and SUS 316L stainless steel. The CaO, Fe2O3, Cr2O3, and SiO2 fluxes used were packed in powdered form. The results indicated that the surface appearance of TIG welds produced with oxide flux formed residual slag. TIG welding with SiO2 powder can increase joint penetration and weld depth-to-width ratio, and therefore the angular distortion of the dissimilar weldment can be reduced. Furthermore, the defects susceptibility of the as-welded can also be reduced.

The optimal control of assembly deviation for large thin-walled structures based on basic deviation patterns

2021 ◽  
pp. 095440542110245
Author(s):  
Chang Gao ◽  
Haidong Yu ◽  
Ke Yuan ◽  
Xinmin Lai
Keyword(s):  
Great Influence ◽  
Optimization Method ◽  
Propagation Model ◽  
Control Points ◽  
Assembly Process ◽  
Thin Walled Structures ◽  
Deviation Propagation ◽  
Thin Walled ◽  
Deviation Pattern ◽  
Assembly Deviation

The deviation vector at arbitrary location of large thin-walled structure caused by manufacturing process is different and has the characteristic of field distribution, which has great influence on the assemble quality. The deviation of each point on the part is not independent, and the final assembly deviation is difficult to be controlled. In this paper, the deviation field of large thin-walled structure is described by the linear combination of a series of basic deviation patterns. The deviation propagation model is established to quantify the contribution of basic deviation patterns between parts and assembly. A new two-step optimization method based on the adjustment of key control points of the part is proposed for the deviation control of large thin-walled structures. Firstly, the effective independent method is employed to obtain the optimal measurement points, which may characterize all basic deviation patterns of the part accurately. Then a new optimization model is developed to determine the key control points for special basic deviation pattern, which have little influence on the other basic deviation patterns. Based on the genetic optimization algorithm, the optimal key control points and the adjusted quantities for special basic deviation pattern are obtained, simultaneously. A case study on the assembly process of two cylindrical thin-walled parts with initial deviations measured by the Laser Scan Device is conducted. The basic deviation pattern with great influence on the deviation of assembly is determined firstly. The key control points and the corresponding adjusted quantities for this basic deviation pattern are calculated. The results indicate that the deviation of the assembled structure may be suppressed by the adjusted deformation of the key control points of parts. It is useful on the deviation control for the assembly process of large thin-walled structures.

scholarly journals Study of coupling configurations of capacitive power transfer system with four metal plates

2019 ◽  
Vol 6 (2) ◽  
pp. 97-112 ◽  
Author(s):  
Qi Zhu ◽  
Shaoge Zang ◽  
Lixiang Jackie Zou ◽  
Guanguan Zhang ◽  
Mei Su ◽  
...  
Keyword(s):  
Electric Field ◽  
Voltage Source ◽  
Transfer System ◽  
Power Transfer ◽  
Modeling And Analysis ◽  
Metal Plates ◽  
Proposed Model ◽  
Aluminum Plates ◽  
Capacitance Matrix ◽  
Good Agreement

AbstractIn this paper, possible coupling configurations of a four-plate capacitive power transfer system are studied by varying the combinations of its input and output ports. A voltage source is applied between two of the four plates, and a load is connected to the other two to form different circuit topologies. A mathematical model based on a 4 × 4 mutual capacitance matrix is established for equidistantly placed four identical metal plates. Based on the proposed model, four separate circuit topologies are identified and analysed in detail and described in a general form. The electric field distributions of the coupling configurations are simulated by ANSYS Maxwell. The theoretical modeling and analysis are then verified by a practical system, in which four aluminum plates of 300 mm × 300 mm are used and placed with a gap of 10 mm between adjacent plates. The experimental results show that the measured output voltage and power under the four coupling configurations are in good agreement with the theoretical results. It has found that the voltage gain is the highest when the two inner plates are connected to the source, and this coupling configuration also has the lowest leakage electric field.

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