ANOVA OF 3D VARIATIONAL MODELS FOR COMPUTER AIDED TOLERANCING WITH RESPECT TO THE MODELING FACTORS

Sheet metal assemblies are subjected to errors as deformations due to material, thickness, geometries and process variations. Advanced simulations enable the optimization of product features, GD&T scheme and assembly process. The 3D error propagation due to the different contributors can be studied with Variational Models of the product and assembly system. However, the practical application of these methods is limited by the high number of factors in the models, which makes the operator experience fundamental to achieve their trustworthiness. Guidelines for modeling the sheet metal assemblies are needed. The present work aims at analysing the variations in the model with a Design of Computer Experiments (DoCE) plan. A case study on an automotive fender is discussed. The results demonstrate that the modeling strategy of clamping operation have the major effects, while the modeling of locators scheme, spot joints and FEM meshing are less important.