Assembly accuracy analysis of cylindrical parts based on skin model shapes considering form deviations and local surface deformations

Assembly accuracy analysis plays a very important role in verifying whether the design scheme of geometric accuracy in the product design stage can meet the functional requirements of mechanical product. Form deviations, position and orientation deviation are inevitable in manufactured parts, and must be considered during assembly accuracy analysis. With regard to the representation of form deviations, it is verified that skin model shapes are effective. However, the existing simulation approaches of skin model shapes for cylindrical parts are mainly based on gaussian random field, without considering the spatial distribution characteristics of form deviations in dealing with the relationship between geometrical and dimensional deviation for cylindrical parts. Especially, when considering local surface deformations of cylindrical mating surfaces generated during the assembly process, the form deviations with different distribution characteristics leads to different contact deformation, which may have further influence on assembly accuracy analysis of cylindrical parts. To address above problems, this paper proposes a simulation method of skin model shapes of cylindrical parts based on Non-Gaussian random field considering the spatial distribution characteristics of form deviations, and the local surface deformations are analyzed with a boundary element method. Based on above, the relative positioning deviation of cylindrical mating surfaces is obtained considering the influence of form deviations and local surface deformations. Finally, the effectiveness of the proposed method is verified with case studies. Specifically, the results of case study reveal that the influences of form deviations considering spatial distribution characteristics and local surface deformations cannot be ignored for assembly accuracy analysis of cylindrical parts. In addition, for the relative positioning deviation of cylindrical mating surfaces for loose fit, the influence of local surface deformations on translational deviations along the x-axis and y-axis is greater than that on rotational deviations around the x-axis and y-axis.