Traditional tolerance analyses such as the worst case methods and statistical are applicable to rigid body assemblies. However, for flexible sheet metal assemblies, traditional not adequate: components can deform, changing dimensions during assembly. This paper evaluates effects of deformation on component tolerances using linear mechanics. Two basic configurations, assembly in series parallel, investigated analytical methods. Assembly sequences multiple joints beyond configurations further...

Online process monitoring in ultrasonic welding of automotive lithium-ion batteries is essential for robust and reliable battery pack assembly. Effective quality algorithms have been developed to identify out control parts by applying purely statistical classification methods. However, such methods do not provide the deep physical understanding manufacturing that necessary diagnostic capability when control. The purpose this study determine correlation between signal features conditions...

One of the major challenges in manufacturing automotive lithium-ion batteries and battery packs is to achieve consistent weld quality joining multiple layers dissimilar materials. While most fusion welding processes face difficulties such joining, ultrasonic stands out as ideal method. However, inconsistency still exists because limited knowledge on formation through interfaces. This study aims establish real-time phenomenological observation multilayer process by analyzing vibration...

This paper studies optimal policy for modular product reassembly within a remanufacturing setting where firm receives returns with variable quality and reassembles products of multiple classes to customer orders. High-quality modules are allowed substitute low-quality during provide the system flexibility such that shortage in lower can be smoothed out by higher module inventories. We formulate problem as Markov decision process characterize structure control policy. In particular, we show...

Energy directors (EDs) have been widely used in ultrasonic welding (UW) of polymers and polymer-based composites. They help concentrate the energy localize weld at location where EDs are present. However, utilization increases manufacturing cost time, especially for complex parts structures. This paper presents a method UW carbon fiber reinforced composite without using EDs. A reusable annular clamp (called blankholder) is as part tool to apply variable force blank holding force) on sheets...

Ultrasonic welding has been widely used in joining plastic parts since it is fast, economical, and suitable for automation. It also great potential thermoplastic composite structures the aerospace automotive industries. For a successful industrial application of ultrasonic welding, necessary to have effective weld quality prediction technology. This paper proposes model by establishing correlation between wave transmission process signatures. The signatures, power, force are directly related...

ABSTRACT The fatigue behaviour of single‐ and double‐rivet aluminum alloy 5754‐O self‐piercing riveted (SPR) lap joints has been investigated experimentally analytically. With the single rivet, experimental program involves a set 27 cyclic tension tests on with 1‐, 2‐ or 3‐mm‐thick sheet coupons. In most cases (85%), cracks are found to initiate in gross section faying surface upper sheet. two rivets (installed rows), consists nine tests, three for each combinations riveting orientation...

The clamping pressure used in assembling a proton exchange membrane (PEM) fuel cell stack can have significant effects on the overall performance. causes deformation, particularly gas diffusion layer (GDL), and impacts mass transfer electrical contact resistance. Existing research for analyzing assembly is mostly experimental. This paper develops sequential approach to study by combining mechanical electrochemical phenomena cells. model integrates analysis based deformed GDL geometry...

Ultrasonic welding is a robust and cost-effective joining method. It can be applied to of metals, polymers composites. Several approaches have been used in the identification relationships between input parameters ultrasonic (e.g., energy, time) joint strength, including experimental methods finite element based prediction. Both these two are accurate but require long lead time for model development. The empirically identified may very complex accuracy prediction sensitive variations...

Sensor signals acquired during the manufacturing process contain rich information that can be used to facilitate effective monitoring of operational quality, early detection system anomalies, and quick diagnosis fault root causes. This paper develops a method for multisensor heterogeneous profile data based on multilinear discriminant analysis. The proposed operates directly multistream profiles then extracts uncorrelated discriminative features through tensor-to-vector projection, thus,...

This paper studies an intentional force increase during the process of resistance spot welding (RSW). Known for decades, forging as a way influencing weld quality has rarely been applied in automotive industry. There little research this area. In paper, effects varying are investigated using both experimental and analytical approaches. Through analysis dynamic electrical resistance, mechanism is explored. study achieves better understanding application shows benefits on quality.

Multilayered ultrasonic welding (USW) is widely used in joining of electrodes or tabs lithium-ion batteries. To achieve quality joints and enhance the process robustness, an improved understanding joint formation highly desirable. In this paper, USW four-layered Ni-coated Cu studied to investigate at a single interface propagation from under both ambient preheated conditions. The results indicate that involves three major mechanisms: Ni–Ni bonding with minimal mechanical interlocking,...

A neural network model is developed for on-line nugget size estimation in resistance spot welding. The variables used consist of features extracted from both controllable process input and signals. systematic signal feature selection procedure developed. three commonly observed signals, dynamic resistance, force, electrode displacement, have been proven to carry similar information. Thus, only the model. obtained has demonstrated be robust over various welding conditions including wear....

Tailor-welded blanks (TWB) are widely used for stamped auto body panels because of their great benefits in weight and cost reduction. However, the weld line a tailor-welded blank causes serious concerns formability material discontinuity additional inhomogeneous stress/strain distribution. This paper proposes holding force (BHF) control strategy to movement, distribute deformation more uniformly thereby improve TWB formability. The methodology is developed based on simplified 2-D sectional...

The productivity of a manufacturing system is greatly influenced by the configuration system. This paper examines importance on productivity, and improvements that can be obtained bufferless parallel-serial configurations, i.e. multiple machining lines in parallel, both with without crossover between operations. Combinatorial algebraic models are developed to quantify configurations. It shown significant placing operations there synergistic improvement from having