... in the geometry assurance process for products containing megacastings in the automotive industry are outlined. The content is divided into “part level” (including geometrical characteristics and part simulation) and “assembly level” (including the joining process and assembly variation simulation). Replacing...

... is the main goal of geometry assurance. To achieve that, variation simulation tools are used to predict variations and optimize manufacturing parameters, to ensure a robust design. In this paper, the most common variation sources linked to the manufacturing process are discussed. Then, variation simulation...

...Soner Camuz; Samuel Lorin; Kristina Wärmefjord; Rikard Söderberg Current methodologies for variation simulation of compliant sheet metal assemblies and parts are simplified by assuming linear relationships. From the observed physical experiments, it is evident that plastic strains are a source...

... or distort during assemble, compliant variation simulation is needed for accurate predictions. In compliant variation simulation, variation in mating points is used to find the rotations and translations of the parts that are assembled. This leads to variation in the boundary conditions when bending...

... will be compared to the more flexible but computationally much heavier direct Monte Carlo (DMC) method, which is not suitable for variation simulation due to the large number of runs required for statistical inference. Two industrial case studies are presented to elicit the need of the proposed method...

... expansion. Fig. 11 The position of 4 measures, to measure mean shift and variation in the x -direction Fig. 12 Above, the result of thermal expansion for 4 measures where 6 standard deviations have been added as vertical bars from a variation simulation. Below, thermal expansion...