Title: Structure configuration/connection impact and design gaps for compliant body assemblies

Authors: B. Zhang, J. Ni

Addresses: Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109, USA. Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109, USA

Abstract: For compliant body assemblies such as automotive and aircraft bodies, design gaps are often given at certain areas in design to avoid interference or to offset potential mean-deviation stack-up. The location, the size and the necessity of design gaps for body assembly are usually based on engineers| experience or the outcomes of previous models. In this paper, the sources for mean deviations are discussed and the structure-induced mean deviation, due to the ||peak contact|| in parallel connection/contact among the components, is identified. It is discovered that the parallel contacts would result in ||mean shifting|| and the resulting variations ||shrinking||. To reduce or eliminate these mean deviations, it is to either consider the impact from product and assembly process design, or specify design gaps if they are necessary. Principle and estimations/calculations of the amounts of design gaps are developed. The study shows that the design gaps are highly related to the structure/connection, contact, assembly process and datum schemes. The work provides insights and practical ways for design engineers to better understand assembly processes and specify design gaps.

Keywords: variation analysis; mean-deviation; design gaps; assembly process; body assembly.

DOI: 10.1504/IJVD.2002.002031

International Journal of Vehicle Design, 2002 Vol.30 No.3, pp.165-180

Published online: 15 Aug 2003 *

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