While variation analysis methods for compliant assemblies are not new, little has been done to include the effects of multi-step, fixtured assembly processes. This thesis introduces a new method to statistically analyze compliant part assembly processes using fixtures. This method, consistent with the FASTA method developed at BYU, yields both a mean and a variant solution. The method, called Piecewise-Linear Elastic Analysis, or PLEA, is developed for predicting the residual stress, deformation and springback variation in compliant assemblies. A comprehensive, step-by-step analysis map is provided. PLEA is validated on a simple, laboratory assembly and a more complex, production assembly. Significant modeling findings are reported as well as the comparison of the analytical to physical results.
College and Department
Ira A. Fulton College of Engineering and Technology; Mechanical Engineering
BYU ScholarsArchive Citation
Stewart, Michael L., "Variation Simulation of Fixtured Assembly Processes for Compliant Structures Using Piecewise-Linear Analysis" (2004). All Theses and Dissertations. 195.
tolerance (engineering), finite element method, statistical tolerance analysis, compliant assemblies, analysis of covariance, manufacturing processes, variation analysis, FASTA, PLEA