Tolerance Analysis for Sheet Metal Assemblies

Abstract

Traditional tolerance analyses such as the worst case methods and the statistical methods are applicable to rigid body assemblies. However, for flexible sheet metal assemblies, the traditional methods are not adequate: the components can deform, changing the dimensions during assembly. This paper evaluates the effects of deformation on component tolerances using linear mechanics. Two basic configurations, assembly in series and assembly in parallel, are investigated using analytical methods. Assembly sequences and multiple joints beyond the basic configurations are further examined using numerical methods (with finite element analysis). These findings constitute a new methodology for the tolerancing of deformable parts.