Finite element (FE) modelling techniques have become a popular tool for exploring welding and clamping sequence dependence in sheet metal assemblies. In the current paper, the dimensional variability associated with different assembly clamping sequences is investigated with a FE contact modelling approach implemented in the commercial code Abaqus. A simplified channel section assembly consisting of a top hat and bottom plate is the case study investigated. Expected variation modes of bow and twist were used to simulate key variability sources in the main structural component under investigation; the top hat of the channel section. It was found that final assembly variability can change considerably depending on clamp sequence selection. It was also found that different clamp sequences can control particular modes of variation better than others, and that there is not one particular clamping sequence that is the best for containing all variation modes. An adaptable assembly process is therefore suggested, where given the shape of input components the best available clamping sequence is selected. Comparison of the performance of the proposed adaptable clamping sequence to traditional fixed clamping sequences shows improvements for the dimensional control of variability in non-rigid components. While introducing such a method in production would require inspection of each component being assembled and investigation of the alternative clamping sequences, given access to fast and detailed dimensional inspection technology such as optical coordinate measuring machines (OCMMu27s), the approach shows promise for future application.
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