Numerical Process Based on Measuring Data for Gap Prediction of an Assembly

The assembly stages enhancement is an important economic challenge for aeronautics industries. After the pre-assembly, gaps exist between components because of compliance and geometrical defects of components. Assembly requirements impose to fill these gaps, without installing internal stresses. A shimming step is currently necessary. It needs gaps measurement, which was identified as a problematic and expensive non-added value stage. Thus the trend is at gap prediction in order to remove gap measurement operations. This paper develops a numerical process allowing predicting gap before assembly step from component measurements. The main issue relates to the integration of measuring data into simulation process. Gap prediction stage is firstly located into the assembly process, in order to define constraints about gap representation. Then gap prediction process principle is detailed, highlighting measuring data integration. This method was subjected to an experimental validation. The entire process was carried out, from component measurement to gap prediction. Several comparisons were achieved to characterize the predicted gap.