Assembly simulation method based on joint optimization of initial pose and contact deformation

Purpose This paper aims to better evaluate assembly accuracy and guide the product design and manufacturing process. By simulating force, deformation, and contact during the assembly process, an assembly simulation method based on the joint optimization of initial pose and contact deformation is proposed. Design/methodology/approach In assembly simulation, high precision skin model samples are constructed based on point cloud features extracted from real surfaces and contact deformation calculation is integrated into the initial attitude solving process to obtain assembly positioning deviations, finally product deviations accumulation is calculated by Jacobi matrix. Findings The assembly simulation method for joint optimization of initial pose and contact deformation is suitable for solving the assembly process of nonideal parts with complex shape deviations. Considering the constraints of surface morphological features and contact deformations, a more realistic assembly position can be obtained. And the validity of the method is verified by plane assembly, which is applied in the tolerance analysis of centrifuges. Originality/value Currently, the main approach to flexible assembly simulation uses a two-step independent strategy: first, the initial rigid contact attitude is calculated, and then the flexible deformation is calculated. However, the determination of the initial rigid assembly attitude is mainly based on geometrical features, ignoring the effect of material flexibility, which simplifies the assembly process. The assembly simulation method proposed in this paper, which simultaneously optimizes the initial contact attitude, contact area and final contact deformation, aims to provide more accurate assembly results for tolerance analysis.