Tolerance simulation of composite wingbox assembly considering preloading-modified distribution

Abstract

Purpose

Tolerance simulation’s reliability depends on the concordance between the input probability distribution and the real variation. The prescribed clamp force introduced changes in parts’ variation, which should be reflected in the input probability distribution for the tolerance simulation. The paper aims to present a tolerance analysis process of the composite wingbox assembly considering the preloading-modified distribution and especially focuses on the spring-in deviation of the thin-walled C-section composite beam (TC2B).

Design/methodology/approach

Based on finite element analysis model of TC2B, the preloading-modified probability distribution function (PDF) of the spring-in deviation is obtained. Thickness variations of the TC2B are obtained from the data of the downscaled composite wingbox. These variations are input to the computer-aided tolerance tools, and the final assembly variations are obtained. The assembly of the downscaled wingbox illustrates the effect of preloading on the probability distribution of the spring-in deviation.

Findings

The results have shown that the final assembly variations estimated with the modified probability distribution is more reliable than the variation of the initial normal distribution.

Originality/value

The tolerance simulation work presented in the paper will enhance the understanding of the composite parts assembling with spring-in deviations, improve the chance to choose assembling processes that allow specifications to be met and help with tolerance allocation in composites assembly.

Citation

Wang, H. and Liu, J. (2016), "Tolerance simulation of composite wingbox assembly considering preloading-modified distribution", Assembly Automation, Vol. 36 No. 3, pp. 224-232. https://doi.org/10.1108/AA-08-2015-067