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Research Papers

Geometry Assurance Integrating Process Variation With Simulation of Spring-In for Composite Parts and Assemblies

[+] Author and Article Information
Cornelia Jareteg, Kristina Wärmefjord, Rikard Söderberg, Lars Lindkvist

Product and Production Development,
Chalmers University of Technology,
Gothenburg SE-412 96, Sweden

Christoffer Cromvik, Johan Carlson, Fredrik Edelvik

Fraunhofer-Chalmers Research Centre,
Chalmers Science Park,
Gothenburg SE-412 88, Sweden

Stig Larsson

Mathematical Sciences,
Chalmers University of Technology,
Gothenburg SE-412 96, Sweden

Contributed by the Design Engineering Division of ASME for publication in the JOURNAL OF COMPUTING AND INFORMATION SCIENCE IN ENGINEERING. Manuscript received September 23, 2015; final manuscript received May 13, 2016; published online August 19, 2016. Editor: Bahram Ravani.

J. Comput. Inf. Sci. Eng 16(3), 031003 (Aug 19, 2016) (7 pages) Paper No: JCISE-15-1298; doi: 10.1115/1.4033726 History: Received September 23, 2015; Revised May 13, 2016

Geometrical variation and deviation in all the manufacturing processes affect the quality of the final product. Therefore, geometry assurance is an important tool in the design phase of a new product. In the automotive and aviation industries where the use of composite parts is increasing drastically, new tools within variation simulations are needed. Composite parts tend to deviate more from nominal specification compared to metal parts. Methods to simulate the manufacturing process of composites have been developed before. In this paper, we present how to combine the process variation simulation of composites with traditional variation simulations. The proposed method is demonstrated on a real complex subassembly, representing part of an aircraft wing-box. Since traditional variation simulation methods are not able to capture the spring-in and the special deviation behavior of composites, the proposed method adds a new feature and reliability to the geometry assurance process of composite assemblies.

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Figures

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Fig. 1

Schematic picture of a composite laminate

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Fig. 2

The spring-in phenomenon shown on an L-beam

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Fig. 3

The spring-in phenomenon shown on a T-beam from the test case used in this paper

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Fig. 4

Principle for thermal expansion simulation shown on a small example mesh with three finite elements: (a) shell mesh, (b) expand to solid mesh, (c) perform simulation, and (d) map solution to shell mesh

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Fig. 5

Schematic 2D view of thermal expansion simulation procedure in a T-beam: (a) assembly shell mesh, (b) create three-parted T-beam solid mesh with the same dimensions, (c) simulate curing, (d) thermal expansion solution on three-parted solid mesh, (e) Map resulting displacements to assembly shell mesh, and (f) thermal expansion solution on assembly shell mesh

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Fig. 6

Thermal expansion simulation procedure in a T-beam of the test case subassembly: (a) assembly shell mesh, (b) create three-parted T-beam solid mesh with the same dimensions, (c) thermal expansion solution on three-parted solid mesh, and (d) thermal expansion solution on assembly shell mesh

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Fig. 7

The test case nominal shell mesh. Aluminum parts are marked, and the rest are composite parts.

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Fig. 8

Schematic picture of the layup used for all the composite parts in the wing-box subassembly

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Fig. 9

Positioning system for all the parts

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Fig. 10

Resulting magnitude of variation using the proposed procedure: (a) scale from min to max value and (b) scale with decreased max value

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Fig. 11

Resulting variation in the y-direction using the proposed procedure: (a) scale from min to max value and (b) scale with decreased max value

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Fig. 12

Variation resulting from only fixture tolerances. The temperature variation is set to zero. (a) Magnitude and (b) Y-direction.

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