Variation Simulation of Multi-station Flexible Assembly based on Finite Element Method

Non-rigid parts are liable to deviate from their nominal position during production in multi-station assembly (MSA) and it is a recognized challenge to simulate these geometric variations reliably. In this paper, a new simulation method is proposed based upon finite element method (FEM). The developed model simulates typical assembly process of placing, clamping, fastening and releasing in multi-stage assembly. It is able to simulate variation from external loads, from contact with mating part, and from springback when the part has been released from the external forces (i.e., of a forming tool). The proposed method is verified through real experiment on assembling a manufacturing part from three flat sheet metal. The proposed method leverages the commercial software ANASYS Workbench and shows big application potential in industrial assembly lines involving large thin-walled parts.