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Modeling method for assembly variation propagation taking account of form error

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Abstract

The propagation of variations, such as fixture errors and datum errors resulting from assembly and machining processes, has been extensively studied. However, only a few studies that focus on form error propagation in assembly systems have been implemented. Machining errors, especially form errors, have great impact on assembly accuracy and accuracy stability of precision mechanical systems. With form errors being the research object, a method for calculating mating variation and specifying mating coordinate is proposed to improve the accuracy of the variation propagation model. Taking into account the form error of mating surfaces, the assembly variation propagation of a precision mechanical system is analyzed, and the brief derivation procedure of the variation propagation model is introduced afterwards. The variation propagation model involves a new concept of mating variation specified by the two mating surfaces. An innovative method, the difference surface search based method, is proposed to calculate the mating variation amongst the mating surfaces. The obtained mating variation is then utilized to specify the mating coordinate in the variation propagation model. Moreover, FEM is employed to simulate the contact state of the two mating surfaces to demonstrate effectiveness of the proposed method. Meanwhile, the mating variation and mating coordinate obtained are incorporated into the assembly variation propagation model, which is then verified by a following case study through a comparison between the calculated results and the experimental results. The comparing results indicate that the established model improves the prediction of assembly accuracy. The developed model enables the investigation of various fundamental issues in variation reduction, including variation analysis, process monitoring, accuracy prediction, and accuracy control.

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Authors and Affiliations

  1. School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China

    Fuchang Zuo, Xin Jin, Zhijing Zhang & Tingyu Zhang

Authors
  1. Fuchang Zuo
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  2. Xin Jin
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  3. Zhijing Zhang
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  4. Tingyu Zhang
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Corresponding author

Correspondence to Xin Jin.

Additional information

This project is supported by National Natural Science Foundation of China (Grant No. 51075035), National Major Scientific Instruments and Equipments Special Project of China (Grant No. 51127004), and National Natural Science Foundation of China (Grant No. 51105036)

ZUO Fuchang, born in 1983, is currently a PhD candidate at School of Mechanical Engineering, Beijing Institute of Technology, China. He received his bachelor degree from China Agricultural University, China, in 2007. His research interests include variation propagation, assembly accuracy prediction and control.

JIN Xin, born in 1971, is currently an associate professor and a master candidate supervisor at School of Mechanical Engineering, Beijing Institute of Technology, China. Her main research interests include micro machining and related fields.

ZHANG Zhijing, born in 1951, is currently a professor and a PhD candidate supervisor at School of Mechanical Engineering, Beijing Institute of Technology, China. His main research interests include precision machining, micro machining, micro measuring and micro assembly.

ZHANG Tingyu, born in 1987, is currently a PhD candidate at School of Mechanical Engineering, Beijing Institute of Technology, China.

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Zuo, F., Jin, X., Zhang, Z. et al. Modeling method for assembly variation propagation taking account of form error. Chin. J. Mech. Eng. 26, 641–650 (2013). https://doi.org/10.3901/CJME.2013.04.641

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  • DOI: https://doi.org/10.3901/CJME.2013.04.641

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