Validation of the Tolerance Analysis of Compliant Assemblies

Current statistical tolerance analysis of assemblies are generally based on Monte Carlo simulation or Worst Case. The available software tools using this technique model the assembly of rigid parts, by only considering the kinematic laws. Sellem (1998) proposed a linear mechanical model taking both deformation and assembly process into account in the computation of tolerance assemblies of compliant parts. This paper presents the validation of this method by a comparison with measurements performed on an actual assembly of four complex parts. Some improvements in the modeling of the assembly process are also presented and described a sensitivity analysis approach to identify the key characteristics of the assembly.