Analyze the Variation From Flexible Parts and Assembly Processes

Compliant vs. Rigid Modeling 

Traditional variation analysis methods are considered to be "rigid-body" or "non-compliant" modeling; meaning, that every part within  the assembly does not flex or would not be distorted through an assembly process such as welding, clamping or unclamping of an assembly fixture.

While this might be the case with a few machined components, most commodities and materials like sheet metal, plastics, aluminum, etc. can be heavily influenced through the manufacturing processes (both fabrication and assembly), thus changing the dimensional integrity or shape of the part/assembly. Finite Element Analysis (FEA) is used to determine the stresses and displacements in mechanical objects and systems, and is the basis for this leading edge advancement in predictive analysis.

3DCS FEA Compliant Modeler, an add-on module to the 3DCS software solutions, utilizes FEA methods to accurately simulate variation of compliant parts and assemblies within the 3D Variation Analysis model.

Optimize Assembly and Manufacturing Processes

Determine optimal placement and order of operation for processes

When welding, bolting, riveting or assembling parts, the order and the process can have as much of an effect on final results as the parts themselves. Riveting can stretch aircraft aluminum skin, assembling can bend and cause spring back, and bolting can warp materials. Simulate, test and determine the best order of operations and the impact these processes will have on your parts. 

 

  • Variation from clamping color map
  • Exhaust system thermal deformation
  • Welding the rails-take into account springback
  • Sag from release of tooling in rear fascia

Analyze the effects of processes like welding, clamping or the release of tooling. Use Finite Element Analysis to accurately predict the material response to forces and heat. 

When Would You Use 3DCS FEA Compliant Modeler?

 

 

Over Constrained Assemblies

How does pressure, force and tooling affect the dimensional quality?

Determine the changes to your product based on constraints, forces and operations. 

 

 

 

 

Clamping and Manufacturing Sequences 

Optimize assembly sequences and order of operation

Test different assembly sequences and processes such as welding, riveting, bolting and clamping to find optimal placements, order of operation and the effect on the assembly. 

 

 

Concentrated Force or Joining of Two Parts

Connect parts with welding or bolting

Determine how welding, bolting and connecting parts affects the dimensional characteristics of your product. Find out how the use of flexible materials like aluminum changes the way your product reacts to manufacturing processes. 

 

 

Gravity, Thermal or Springback

Parts sag from their weight, or expand when welded or in use. Automotive hoods flex and bend to product springback force, and aluminum skin in aircraft stretches and distorts when riveted. Determine how these processes and forces affect your product's quality, and account for it through process change, tolerance changes or tooling. 

Analyze the effect of manufacturing processes

Calculate the variation from forces such as heat and gravity

Add to existing 3DCS models and analyses

Interested in seeing for yourself? Fill out the form below to get a free demonstration of 3DCS FEA Compliant Modeler.


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