Research Papers

Efficient Compliant Variation Simulation of Spot-Welded Assemblies

[+] Author and Article Information
Samuel Lorin

Computational Engineering and Design,
Fraunhofer Chalmers Centre,
Gothenburg SE-412 58, Sweden
e-mail: samuel.lorin@fcc.chalmers.se

Björn Lindau

81710, ME - Core Geometry,
Volvo Car Corporation,
Gothenburg SE-405 31, Sweden

Lars Lindkvist, Rikard Söderberg

Department of Industrial and Materials Science,
Chalmers University of Technology,
Gothenburg SE-412 96, Sweden

1Corresponding author.

Contributed by the Computers and Information Division of ASME for publication in the JOURNAL OF COMPUTING AND INFORMATION SCIENCE IN ENGINEERING. Manuscript received May 7, 2018; final manuscript received October 1, 2018; published online November 19, 2018. Assoc. Editor: Charlie C. L. Wang.

J. Comput. Inf. Sci. Eng 19(1), 011007 (Nov 19, 2018) (7 pages) Paper No: JCISE-18-1117; doi: 10.1115/1.4041706 History: Received May 07, 2018; Revised October 01, 2018

During product development one important aspect is the geometric robustness of the design. This is due to the fact that all manufacturing processes lead to products with variation. Failing to properly account for the variability of the process in the design phase may lead to expensive redesign. One important tool during the design phase in many industries is variation simulation, which makes it possible to predict and optimize the geometric quality of the design. However, despite the increase in computer power, calculation time is still an obstacle for the wider use of variation simulation. In this article, we propose a new method for efficient compliant variation simulation of spot-welded sheet metal assemblies. The method is exact, and we show that the method leads to time savings in simulation of approximately 40–50% compared to current state-of-the-art variation simulation.

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Grahic Jump Location
Fig. 1

Geometry assurance [2]

Grahic Jump Location
Fig. 2

To the left, a part is forced into position by a clamp (in gray, from above and below). To the right is a cross section of what is happening. The shape before clamping is shown in orange, green shows the clamped position of the non-nominal part and the clamps are shown in gray.

Grahic Jump Location
Fig. 3

Case 1: the red arrows indicate the positioning system (A1–A3, B1, B2, and C3), the orange arrows are support points (S1, …, S17) and the gray dots are weld point pairs (W1, …, W11)

Grahic Jump Location
Fig. 4

Case 2 with positioning system (A1–A3, B1, B2, and C3), support points (S1, …, S17) and weld point pairs (W1, …, W12)

Grahic Jump Location
Fig. 5

Case 3 with positioning system (A1–A3, B1, B2, and C3), support points (S1, …, S14)



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