Dimensional Variation Analysis of Compliant Sheet Metal Assembly

In order to assure the dimensional quaLity of compLiant sheet metal assembly, it is quite necessary to use the numerical method to simulate and analyze the assembly process before real assembly. In this paper, the finite element analysis of the whole compLiant sheet metal assembly process is reaLized in two steps: clamping force calculation and joining and springing back simulation. Clamping force is optimized so that the initial gap between parts can be closed. The joints of the two parts are simulated by DOF coupLing in ANSYS. Spring-back force, which is assumed to be equal to the optimum clamping force, is appLied on the joint points. Large displacement static analysis is run in ANSYS to calculate the displacement distribution of both clamped part and compLiant sheet metal assembly. An example of compLiant sheet metal assembly by lap joints is studied to demonstrate the finite element analysis process in this paper.