Solid riveting process optimization for the reduction of key point distortions caused by locating

Abstract

Purpose Determinative locating and riveting distortions are highly coupled at assembly locale. Recent methods only take every tested or assumed locating errors at the mating surface into the process planning for the assemblies in a simple form. However, the growth of part number makes it nearly infeasible to take every locating error at every mating surface into the dimensional precision calculation. This paper aims to provide a solid riveting process planning for the reduction of practical locating-related distortions. Design/methodology/approach Large-scale metrology firstly measures the determinative coordinates for the locating-deviated key points. Iterative finite element (FE) analyses then calculate the riveting-related key point distortions from every rivet upsetting directions (UDs) and assembly sequence. These key points on the actual assembly contour and relative FE nodes yield two virtual planes. Virtual plane manipulation adds the riveting distortions into the locating-deviated coordinates. Finally, optimal algorithm integrates the iterative FE analyses with virtual plane manipulation. Findings Case studies validate that the virtual plane manipulation coincides with the test well, and the proposed method has good compensation of practical locating distortion. Research limitations/implications The optimized rivet UDs may be set in a chaotic distribution, which may complicate the abundant riveting operations and the assembly appearance. Therefore, the use of automatic riveting systems can overcome the operational complexity, and the industrial design of rivet UD distribution will improve the assembly appearance. Practical implications The optimized UDs and assembly sequence are for assembly workers or automatic riveting systems. Originality/value The proposed method is the first to reduce the determinative locating distortion by a novel and efficient solid riveting process planning in detail, and the solid riveting process designed is conservative and accurate for practice.