Optimal design of fixture layouts for compliant sheet metal assemblies
Journal article, 2020

A preeminent factor in the geometrical quality of a compliant sheet metal assembly is the fixture layout that is utilized to perform the assembly procedure. Despite the presence of a great number of studies about the optimization of assembly fixture layouts, there is not a comprehensive algorithm to optimize all design parameters of fixture layouts for compliant sheet metal assemblies. These parameters are the location and type of hole and slot in each part, the slot orientation, and the number and location of additional clamps. This paper presents a novel optimization method that optimizes all these parameters simultaneously to maximize the geometrical quality of the assemblies. To attain this goal, compliant variation simulations of the assemblies are utilized along with evolutionary optimization algorithms. The assembly springback and contacts between parts are considered in the simulations. After determining the optimal design parameters, the optimal positions of locators are fine-tuned in another stage of optimization. Besides, a top-down design procedure is proposed for applying this method to multi-station compliant assemblies. The presented method is applied to two industrial sample cases from the automotive industry. The results evidence a significant improvement of geometrical quality by utilizing the determined fixture layout from the presented method compared with the original fixture layouts of the sample cases.

Sheet metal assemblies

Fixture layout optimization

Compliant variation simulations


Abolfazl Rezaei Aderiani

Chalmers, Industrial and Materials Science, Product Development

Kristina Wärmefjord

Chalmers, Industrial and Materials Science, Product Development

Rikard Söderberg

Chalmers, Industrial and Materials Science

Lars Lindkvist

Chalmers, Industrial and Materials Science, Product Development

Björn Lindau

Volvo Cars

International Journal of Advanced Manufacturing Technology

0268-3768 (ISSN) 1433-3015 (eISSN)

Vol. 110 7-8 2181-2201

Smart Assembly 4.0

Swedish Foundation for Strategic Research (SSF) (RIT15-0025), 2016-05-01 -- 2021-06-30.

Subject Categories

Mechanical Engineering

Production Engineering, Human Work Science and Ergonomics

Manufacturing, Surface and Joining Technology



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