Design evaluation of sheet metal joints for dimensional integrity

The design of joints between parts is one of the most critical issues in the design of sheet metal assemblies. This paper presents a new part-to-part joint design evaluation index developed for dimensional control of sheet metal assemblies. The proposed index provides a new analytical tool to address the; dimensional capabilities of an assembly process in the early product design stage. It covers the three basic types of joints, which encompass the whole domain of joints used in sheet metal assembly. The part-to-part interactions for each type of joint are studied, and an analytical model is provided. Two evaluation indices, (1) product joint design evaluation and (2) critical part determination are developed. The developed methodology is demonstrated using two industrial design examples of sport-utility automotive bodies.