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An Aerospace
Manufacturing
Perspective
Course Overview
Introduction
Assembly Concepts
Constraint
Fixtures
Assembly features
Tolerance stacks
Assembly
What happened""
Too slow and too costly
No one knew how to do an economic
analysis and most didnt care at first
People do what they do because of
their strengths and weaknesses - same
with robots
Today there is a place for robots,
people, and fixed automation in
assembly
The issue is to decide which is best
and how to prepare the environment
Assembly = Constraint
1. Assembly = removal of dof =
application of constraint
2. As constraint is applied, degrees
of freedom are taken away so that
a part gets to where it is
supposed to be.
3. When parts are where they are
supposed to be, the key
characteristics of the assembly
can be delivered, assuming no
variation
4. This is called the nominal design
copyright J. Anderson, 2008
Constraint is Accomplished by
Surfaces in Contact
Degrees of Freedom
An object's location in space is completely
specified when three translations (X, Y, Z)
and three rotations (X,Y, Z ) are specified
How many DOFs are constrained for a cube
on table (x-y plane)?
- rotation about x & y and translation
along z; therefore 3 degrees of
freedom are constrained
Assembly Constraint
1. Proper constraint provides a single value for each
of a bodys 6 degrees of freedom (dof)
2. This is done by establishing surface contacts with
surfaces on another part or parts
3. If less than 6 dof have definite values, the body is
under-constrained
4. If an attempt is made to provide 2 or more values
for a dof, then the body is over-constrained
because rigid bodies have only 6 dof
5. Any extra needed dof must be obtained by
deforming the object
copyright J. Anderson, 2008
"Good" Over-constrained
Assemblies
Preloaded angular contact bearing systems
Preload increases contact stress, creating a stiff bearing
system (see next page)
Stabilizer structure
copyright J. Anderson, 2008
Typical Tool on
Storage Rack
Cure Liquid
Shim
Current Cure
Time is 8 Hours
Remove Skin
Using Hard
Tool
Install Skin
Inspect Liquid
Shim and Repair
Using Hard
Tool
Inspect Holes
Using Renishaw
Probe
Move Structure
into Workstand
Install Fasteners