A systematic approach in analyzing dimensional variation of flexible structures for automobile body structure

This thesis presents a systematic method of analyzing dimensional variation of flexible structure used in automobile body structures. During the assembly processes, any dimensional variation from the assembly components may cause variation on the final dimension of the assembled structure. Even though the tolerances have been assigned to the components, some manufacturing variables such as spot welding and clamping can induce problems.;The method is developed into two major engineering analysis approaches, analysis method in the early design stage and during the manufacturing process. The first method was used to develop an approximate assembly function which takes into account the spot welding process and flexibility property of the structures. Finite Element Method was used to model the structures and simulate the spot welding process. Multivariate analysis technique was used to analyze the dimensional variation during the manufacturing processes.;This systematic method is a useful tool for achieving robust design. The method can also be used to any flexible structure design and assembly process.