In this paper we investigate the suitability of the GapSpace assembly analysis method [1] for assemblies in which there is interference between the components. Of particular interest are assemblies in which there are several sets of features that can influence the final location of the parts, once assembled. Our analysis includes using the finite element method to estimate the work required for assembly and the total strain energy in the components after assembly is complete. We then examine how these values can be predicted for different part geometries that can arise for a particular specification of part tolerances. The goal of this work is to provide fast approximations of force/work/energy calculations for designers of assemblies in which interference is required.

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